Metallic LED Mounting Spring for Heat Sink Thermal Coupling
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Solution Overview
Problem
Existing plastic devices that secure LED light sources to heat sinks rely solely on screw torque, which fails to provide a suitable and even force initially and degrades over time due to material degradation, leading to inadequate thermal coupling.
Innovation Solution
Integration of a force-applying spring into the LED light engaging surface, typically in the form of leaf-spring like mounting tabs or a curved configuration, to uniformly push the LED light against the heat sink, ensuring better thermal coupling and durability through a metallic construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If plastic devices rely solely on screw torque to secure LED light sources, then the device complexity is reduced, but the force application becomes uneven and degrades over time
Solution Approach 1:
The patent changes the material parameter from plastic to metal and introduces a spring element to alter the force application mechanism. The spring constant and metal material properties enable consistent force application that does not degrade over time, resolving the reliability issue while maintaining reasonable device complexity
Solution Approach 2:
The mounting device is segmented into distinct functional components: a metal body structure and separate spring elements. This segmentation allows each component to perform its specific function optimally - the metal body provides structural support while the springs provide consistent forcing, thereby improving reliability without significantly increasing overall complexity
2Ease of manufacture
If plastic mounting devices are used, then the ease of manufacture is improved, but thermal degradation occurs over time
Solution Approach 1:
The patent changes the material parameter from plastic to metal, fundamentally altering the material stability characteristic. Metal materials exhibit superior thermal stability and resistance to degradation, directly addressing the material stability issue while remaining manufacturable through conventional metal forming processes
3Device complexity
If screw torque alone is used for mounting, then the device complexity is minimized, but thermal coupling is inadequate
Solution Approach 1:
The patent introduces a spring element that changes the contact pressure parameter between the LED light source and heat sink. The spring maintains optimal contact pressure for thermal coupling, ensuring efficient heat transfer while the metal construction provides the necessary structural support, thereby improving thermal coupling without excessive increase in device complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a consistent and even engagement between the LED light source and the heat sink, enhancing thermal coupling and maintaining performance over time without thermal degradation, as the metallic components resist material degradation.
Implementation Method 1
Integration of a force-applying spring into the LED light engaging surface, typically in the form of leaf-spring like mounting tabs or a curved configuration, to uniformly push the LED light against the heat sink
Data Source
AI summary
A device for securing a source of LED light to a heat sink includes an LED light source engaging surface that is arranged and configured to engage at least a portion of the source of LED light and which is provided with an integrated force applying spring. Further, the device may include a continuous metallic path extending between the sources of LED light and the surface.