LED Power Supply Insert Eliminates Folded Circuit Breakage

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Solution Overview

Problem

Existing power supply devices for light sources and electronic components, when arranged on either side of a third-party component like a heat sink, face inefficiencies in power supply and size, and are costly and unreliable due to the need for folded driver circuits that are prone to breakage.

Innovation Solution

A power supply device with an electrically conductive insert in its housing, allowing access to power on the opposite side of the conductive track, eliminating the need for bending the driver circuit and reducing costs, while using materials like aluminum or copper alloys for the insert to facilitate reliable electrical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the driver circuit is folded to fit on either side of the heat sink, then the power supply can reach components on both sides, but the circuit becomes prone to breakage at bend lines and requires costly prior machining

Engineering Contradiction:

Improvepower supply accessVSAvoidcircuit reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The driver circuit is divided into two separate uncoped circuits, each mounted on one side of the heat sink. This eliminates the need to fold a single circuit around the heat sink, removing stress concentration points and improving reliability while maintaining power supply access to both sides.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A third-party component (such as a via or conductive structure) is introduced to bridge the electrical connection between the two uncoped driver circuits on opposite sides of the heat sink. This intermediary allows power supply access through the heat sink without requiring the driver circuit itself to be folded or machined.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the driver circuit is folded beforehand to fit around the heat sink, then power supply access is achieved, but additional machining costs and manufacturing complexity are incurred

Engineering Contradiction:

Improvepower supply accessVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The driver circuit is segmented into two separate uncoped circuits mounted on opposite sides of the heat sink, eliminating the need for costly prior folding and machining operations. Each circuit can be manufactured independently using standard PCB fabrication processes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A third-party conductive component serves as an intermediary to establish electrical connection between the two uncoped circuits, replacing the need for expensive custom machining and folding operations while simplifying manufacturing.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If the driver circuit is folded to accommodate the heat sink, then power supply connection is established, but the ratio of useful surface area to total volume decreases

Engineering Contradiction:

Improvepower supply connectionVSAvoiduseful surface area

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The driver circuit is segmented into two separate uncoped circuits, each occupying its own surface area on opposite sides of the heat sink. This eliminates the waste of surface area associated with folded circuits and maximizes the useful area available for circuit traces and components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A third-party component provides the connection through the heat sink, allowing both driver circuits to maintain full surface area utilization without the need for folding that would reduce useful area.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 provides a compact, reliable, and cost-effective power supply for both light sources and electronic components, reducing the risk of breakage and improving efficiency by eliminating the need for folded circuits.

Implementation Method 1

an electrically conductive insert (48), received in a housing (50) for receiving the control circuit (46), and electrically connected to said conductive track

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentEP3383150B1Power supply device for at least one LED and at least one electronic component, comprising a power supply control circuit provided with an insert

Publication Date: 2022.04.20 VALEO ILUMINACION SA

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AI summary

The present invention relates to a power supply device (40) for at least one light source (16A) of the light-emitting diode type and at least one electronic component (16B), comprising: - a control circuit for the power supply of the or each light source, the control circuit (46) comprising at least one electrically conductive track and a receiving housing (50) for an insert (48); - an insert (48) made of electrically conductive material, said insert being inserted into the receiving housing and comprising a first end portion (53) electrically connected to the conductive track, and a second end portion (54) adapted to be electrically connected to at least one electronic component (16B), for the power supply of said electronic component.