LED Mounting Spring for Even Thermal Contact
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Solution Overview
Problem
Existing plastic devices that secure LED light sources to heat sinks rely solely on screw torque, leading to inadequate initial engagement and degradation over time, resulting in uneven contact and poor thermal coupling.
Innovation Solution
Integration of a force-applying spring into the LED light engaging surface, typically using leaf-spring like mounting tabs or a curved configuration, to uniformly push the LED light against the heat sink, ensuring even engagement and improved thermal coupling.
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 engagement evenness and thermal coupling deteriorate over time
Solution Approach 1:
The patent introduces a spring mechanism that transforms the static screw torque connection into a dynamic system. The spring can compress and exert continuous force on the LED light source, adapting to thermal expansion and material degradation over time, thereby maintaining even engagement and reliable thermal coupling throughout the product lifecycle
Solution Approach 2:
The patent changes the physical state of the mounting mechanism by introducing elastic deformation through the spring. The spring's compression parameter changes under load, allowing it to distribute force evenly across the LED light source surface and maintain consistent contact pressure despite changes in screw torque or material properties over time
2Manufacturing precision
If plastic devices use only screw torque, then the manufacturing precision requirements are reduced, but the thermal coupling and force distribution worsen
Solution Approach 1:
The patent employs a spring element that acts as a flexible component between the rigid screw connection and the LED light source. This flexible element can deform to accommodate manufacturing tolerances and surface irregularities, ensuring uniform contact and effective thermal coupling without requiring extremely tight manufacturing precision
Solution Approach 2:
The spring serves as an intermediary element between the screw fastening system and the LED light source. It mediates the force transmission and thermal conduction, distributing the clamping force evenly across the LED surface and maintaining optimal thermal contact despite variations in manufacturing precision or assembly conditions
3Ease of manufacture
If plastic material is used for the securing device, then the ease of manufacture is improved, but the force application consistency deteriorates due to material degradation
Solution Approach 1:
The patent creates a composite mounting structure combining plastic components with a metal or durable polymer spring element. This composite design leverages the ease of plastic manufacturing for the housing while incorporating a more durable spring material that resists degradation and maintains consistent force application over the product's operational lifetime
Solution Approach 2:
The spring mechanism provides beforehand cushioning against material degradation by maintaining constant contact force. As the plastic components may degrade over time, the spring's elastic properties compensate for these changes, ensuring consistent force application and thermal coupling throughout the intended service life of the LED lighting product
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 durable force distribution that enhances thermal coupling between the LED light and the heat sink, maintaining effective engagement without the degradation issues of plastic materials.
Implementation Method 1
the LED light engaging surface includes an integrated spring, which functions to generally, uniformly push the source of LED light against the surface of 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.