LED Mounting Arrangement Thermal Coupling Without Screws

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Solution Overview

Problem

Existing mounting arrangements for LED lighting devices require additional mechanical components and complex assembly processes, increasing costs and production time due to the need for screws and washers to achieve thermal and mechanical coupling.

Innovation Solution

A mounting arrangement using a housing, reflector, and a cover with snap-in elements that provide mechanical and thermal coupling without screws, allowing for a stable and efficient assembly process with reduced components, where the cover exerts pressure on the reflector to push the PCB against the housing, ensuring thermal contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If screws and washers are used to achieve thermal and mechanical coupling between LED module and housing, then thermal contact is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvethermal contact qualityVSAvoidnumber of mechanical components

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent merges the thermal coupling function and mechanical retention function into a single integrated housing structure. The housing directly contacts the LED module to provide thermal coupling while simultaneously retaining it through the housing's structural design, eliminating the need for separate screws and washers.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing is designed to perform multiple functions: it serves as both the thermal path for heat dissipation and the mechanical structure for retaining the LED module. This multi-functionality reduces the total number of components needed in the assembly.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If screws and washers are used to achieve thermal and mechanical coupling, then thermal contact is improved, but assembling time and production cost increase

Engineering Contradiction:

Improvethermal contact qualityVSAvoidassembling time

Core Design Contradiction:

TemperatureVSLoss of time

Solution Approach 1:

By combining thermal coupling and mechanical retention into a single housing structure, the assembly process requires only one assembly operation instead of multiple steps involving screws and washers, significantly reducing assembling time.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts the unnecessary mechanical fastening components (screws and washers) from the assembly, retaining only the essential housing structure that provides both thermal and mechanical functions, thereby simplifying the assembly process.

Inventive Principle:

Principle #2Taking out (Extraction)

3Temperature

If PCB directly contacts housing for thermal coupling, then thermal management is improved, but PCB reliability decreases due to thermal stress

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidPCB lifespan

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The housing acts as an intermediary between the PCB and the heat sink function. It provides the thermal path for heat dissipation while isolating the PCB from direct contact with the housing, thereby protecting the PCB from thermal stress and mechanical stress.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent segments the thermal management function from the structural support function. The housing provides structural support and retains the LED module, while a separate thermal path (through the housing structure) handles heat dissipation, preventing thermal stress on the PCB.

Inventive Principle:

Principle #1Segmentation

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

This solution simplifies the assembly process, reduces production costs, and maintains effective thermal and mechanical coupling, improving the reliability and safety of the LED lighting device by eliminating direct contact between the PCB and housing, thus maintaining lower operating temperatures and extending the device's lifespan.

Implementation Method 1

a reflector to reflect light from said source towards said opening

Methodology Applied

Scientific EffectLight reflection: Reflection

Implementation Method 2

The cover exerts pressure on the reflector to push the PCB against the housing, ensuring thermal contact

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS8678621B2Mounting arrangement for lighting devices, corresponding lighting devices and method

Publication Date: 2014.03.25 OPTOTRONIC GMBH

AI summary

A mounting arrangement for a light source (L) having associated a Printed Circuit Board, wherein said mounting arrangement includes: a housing (H) with an exit opening for light from the source (L), a reflector (R) to reflect light from the source (L) towards the opening, an at least partly transparent cover (1) to close the opening of the housing (H). The cover (1) includes a set of retaining elements (12A) for retaining the cover (1) to the housing (H), and a set of holding elements (12B) for holding the associated Printed Circuit Board (D) within the housing (H). Such configuration is capable of exerting a pressure on the reflector (R) when the cover (1) is coupled to the housing (H), and wherein the reflector (R) in turn urges the light source (L) against the housing (H), providing thus thermal coupling between the light source (L) and the housing (H).