LED Illumination Module Thermal Interface and Vented Reflector

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Solution Overview

Problem

LED-based illumination devices require large heat sinking and specific power requirements, making their mounting to light fixtures user-unfriendly and inefficient.

Innovation Solution

An LED-based illumination module with a thermal interface surface coupled to a reflector using engaging members that generate compressive force, allowing for efficient heat dissipation through a vented portion that is not optically coupled to the LED module, enabling easy installation and removal of a top-facing heat sink.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If LED-based illumination devices are mounted to light fixtures with heat sinks, then heat dissipation is improved, but installation complexity and user-friendliness deteriorate

Engineering Contradiction:

Improveheat dissipationVSAvoidinstallation complexity

Core Design Contradiction:

TemperatureVSEase of operation

Solution Approach 1:

The patent combines the heat sink, reflector, and illumination module into a single integrated assembly. The heat sink is thermally coupled to the LED module, the reflector is optically coupled to direct light, and all components are pre-assembled with mounting features, eliminating the need for separate installation of multiple components and reducing installation complexity while maintaining effective heat dissipation

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated assembly is designed as a modular unit that can be easily installed and removed as a single component. This segmentation allows the entire heat management and light distribution system to be replaced or adjusted without complex procedures, improving user-friendliness while maintaining thermal performance

Inventive Principle:

Principle #1Segmentation

2Temperature

If engaging members generate compressive force between thermal interface surfaces, then thermal contact is improved, but device complexity increases

Engineering Contradiction:

Improvethermal contactVSAvoidmounting mechanism complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The engaging members are designed to automatically generate compressive force when the illumination module is installed. The spring pins or elastic clips engage with corresponding features on the heat sink and reflector, self-adjusting to create the necessary thermal contact pressure without requiring additional adjustment mechanisms or complex mounting procedures

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces complex mechanical fastening systems with simpler elastic or spring-based engaging members. These members use material elasticity rather than multiple fasteners or adjustment mechanisms to achieve and maintain thermal contact, reducing device complexity while ensuring adequate thermal interface

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Temperature

If a vented portion is added to the reflector for air flow, then heat dissipation is improved, but optical performance may deteriorate

Engineering Contradiction:

Improveheat dissipationVSAvoidoptical performance

Core Design Contradiction:

TemperatureVSIllumination intensity

Solution Approach 1:

The vented portion is strategically positioned in a location on the reflector that does not interfere with the optical path or light distribution. This localized modification allows air flow for heat dissipation while maintaining the reflector's optical performance in the critical light-emitting regions, achieving both thermal management and optical functionality

Inventive Principle:

Principle #3Local quality

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 enhances heat dissipation, improves user-friendliness in mounting, and allows for higher power driving of LEDs while maintaining uniform light distribution.

Implementation Method 1

a thermal interface surface that is coupled to a thermal interface surface of a reflector using engaging members that generate a compressive force between the thermal interface surfaces

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The reflector may include a vented portion that is not optically coupled to the LED based illumination module to allow air to pass through the reflector

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS9217560B2Reflector attachment to an LED-based illumination module

Publication Date: 2015.12.22 SBC XICATO CORP

AI summary

An LED based illumination module includes a thermal interface surface that is coupled to a thermal interface surface of a reflector using engaging members that generate a compressive force between the thermal interface surfaces. The engaging members may be, e.g., protrusions that interface with recesses, spring pins, formed sheet metal, magnets, mounting collar, etc. The reflector may include a vented portion that is not optically coupled to the LED based illumination module to allow air to pass through the reflector.