LED Lighting with Sheet Metal Heat Sink and Adhesive Mounting
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Solution Overview
Problem
LED-based lighting systems face reduced efficiency, brightness, and lifespan due to inadequate heat dissipation, which can also cause changes in color temperature if heat is not properly managed.
Innovation Solution
The use of a sheet metal member with an adhesive layer to attach LED components and wires, providing a large heat sink for effective heat dissipation and serving as both a support structure and heat sink, thereby reducing the need for additional heat dissipation structures and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If LEDs are used for energy efficient lighting, then energy consumption is reduced, but heat generation increases causing reduced efficiency and lifespan
Solution Approach 1:
The patent combines the support structure and heat dissipation function into a single integrated metal sheet member. The LEDs are mounted directly on this metal sheet which serves dual purposes: structural support and thermal management. This merging eliminates the need for separate heat sinks while effectively dissipating the heat generated by the energy-efficient LEDs.
Solution Approach 2:
The metal sheet member performs multiple functions simultaneously: it provides mechanical support for the LEDs and wires, acts as a heat dissipation pathway, and serves as a mounting substrate. This multi-functionality addresses the heat generation issue while maintaining the energy efficiency benefits of LED technology.
2Temperature
If additional heat dissipation structures are added, then heat dissipation is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
Instead of adding separate heat dissipation structures, the patent merges the heat dissipation function into the existing support structure. The metal sheet member that provides structural support also serves as the heat dissipation pathway, thereby improving heat dissipation without increasing device complexity or manufacturing cost.
Solution Approach 2:
The metal sheet member is designed to perform multiple functions: structural support and heat dissipation. By making the support structure universal and multi-functional, the patent avoids the need for additional specialized heat dissipation components, thus maintaining simplicity while achieving effective thermal management.
3Temperature
If separate support structure and heat sink are used, then heat dissipation is effective, but manufacturing cost and complexity increase
Solution Approach 1:
The patent combines the support structure and heat sink into a single metal sheet member. This integration maintains effective heat dissipation capabilities while reducing the number of separate components that need to be manufactured and assembled, thereby lowering manufacturing costs and simplifying the production process.
Solution Approach 2:
The metal sheet member is designed as a universal component that provides both mechanical support and thermal management functions. This multi-functionality eliminates the need for separate heat sink components, reducing manufacturing complexity and cost while maintaining effective heat dissipation.
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, maintains LED efficiency and brightness, and extends lifespan while reducing manufacturing costs by integrating the sheet metal member as both a support and heat sink, adaptable for various applications.
Implementation Method 1
An adhesive layer is directly attached to the first surface of the sheet metal member. A plurality of light-emitting diode (LED) components are attached to the sheet metal member by the adhesive layer.
Implementation Method 2
The sheet metal member...providing a large heat sink for effective heat dissipation
Data Source
AI summary
A disclosed lighting apparatus includes a support structure having a sheet metal member. The sheet metal member has a first surface. An adhesive layer is directly attached to the first surface of the sheet metal member. A plurality of light-emitting diode (LED) components are attached to the sheet metal member by the adhesive layer. A plurality of wires are attached to the sheet metal member by the adhesive layer and are coupled to the plurality of LED components for providing power to the LED components.