LED Mounting Tabs with V-Shaped Leaf Springs for Thermal Contact
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Solution Overview
Problem
Existing devices that secure LED light sources to heat sinks fail to provide even engagement initially and over time due to material degradation, leading to uneven contact and potential thermal issues.
Innovation Solution
A device with a curved LED light source engaging surface and integrally formed mounting tabs, including v-shaped leaf-spring like structures, applies uniform force to the LED light source, ensuring even engagement with the heat sink surface, utilizing resilient materials like metal to maintain force distribution without degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw torque is used to secure LED light source to heat sink, then initial engagement is achieved, but even engagement deteriorates over time due to material degradation
Solution Approach 1:
The mounting tabs are designed as resilient elements that can dynamically adjust and maintain even engagement force on the LED light source over time. The tabs flex to compensate for thermal expansion and material degradation, ensuring consistent contact pressure between the LED and heat sink surface throughout the operational lifespan.
Solution Approach 2:
The resilient mounting tabs change their physical state from rigid to flexible, allowing them to adapt to thermal cycling and material degradation. This parameter change enables the tabs to maintain optimal engagement force across varying operating conditions and extended time periods.
2Strength
If rigid mounting structure is used to secure LED light source, then structural strength is achieved, but even force distribution is lost
Solution Approach 1:
The mounting tabs function as flexible elements that conform to the LED light source surface and heat sink interface. This flexibility enables uniform force distribution across the contact area while maintaining sufficient mounting strength to secure the LED assembly.
Solution Approach 2:
The mounting structure combines rigid support functions with flexible force-distribution functions through the integration of resilient mounting tabs with the mounting device body, creating a composite system that achieves both strength and uniformity.
3Ease of manufacture
If simple mounting structure is used to secure LED light source, then ease of manufacture is achieved, but thermal management performance deteriorates
Solution Approach 1:
The resilient mounting tabs act as an intermediary element between the mounting structure and the LED light source, ensuring optimal thermal contact without complicating the overall manufacturing process. The tabs conform to surface irregularities, improving thermal interface quality while maintaining manufacturing simplicity.
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 more even and consistent engagement between the LED light source and the heat sink, maintaining force distribution over time and usage, preventing thermal issues and ensuring reliable performance.
Implementation Method 1
the resilient mounting tabs will apply a force upon the source of LED light
Implementation Method 2
the LED light source engaging surface is curved upwardly towards the first and second ends whereby the LED light source engaging surface will apply a force upon the source of LED light to generally, uniformly push the source of LED light against the surface of the heat sink
Data Source
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AI summary
A device for securing a source of LED light to a heat sink includes a LED light source engaging surface that is arranged and configured to engage a least a portion of a the source of LED light and which is provided with an integrated force applying spring.