Fork-Shaped LED Support with Interference Fit Heat Sink
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Solution Overview
Problem
Existing lighting devices with solid-state light sources, such as LEDs, face challenges in achieving effective mechanical and thermal coupling without the use of additional elements like adhesives or fixation members, particularly when mounting the light engine onto a heat sink.
Innovation Solution
A lighting device design featuring a fork-shaped laminar support member with bent prongs that incorporate light radiation sources and an optional optical element, where a heat sink is mounted through an interference fit, eliminating the need for additional fixation means by using a clamping action and potentially adhesive material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fixation members, glues, or biadhesive tapes are used to mount the light engine onto the heat sink, then the mechanical coupling is improved, but the device complexity and cost increase
Solution Approach 1:
The support element is designed with an integrated clamping structure that combines mechanical support and fixation functions into a single component. The fork-shaped support element with bent prongs creates a self-contained mounting system that eliminates the need for separate fixation members, glues, or tapes, thereby reducing device complexity while maintaining mechanical coupling strength
Solution Approach 2:
The support element's clamping structure is designed to self-align and self-secure the light engine onto the heat sink. The bent prongs create a self-retaining mechanism that automatically provides mechanical coupling without requiring additional fixation elements, reducing both complexity and cost
2Strength
If additional elements like adhesives or fixation members are used, then the mechanical coupling is improved, but the manufacturing cost increases
Solution Approach 1:
The support element integrates multiple functions (support, positioning, and fixation) into a single component, eliminating the need for separate adhesives or fixation members. This reduction in part count directly lowers manufacturing costs while maintaining the necessary mechanical coupling strength
Solution Approach 2:
The invention replaces expensive additional fixation elements with a simple, integrated clamping structure made from the same support element material. This approach uses readily available materials and simple forming processes to create an cost-effective solution that achieves the required mechanical coupling
3Device complexity
If a simple mounting method is used, then the device complexity is reduced, but the thermal coupling efficiency may worsen
Solution Approach 1:
The clamping structure is designed with specific local features (bent prongs with contact surfaces) that concentrate thermal contact at critical interfaces. The support element makes direct thermal contact with both the light engine and heat sink at specific locations, ensuring efficient heat transfer while maintaining overall structural simplicity
Solution Approach 2:
The support element is designed to provide both mechanical support and thermal conduction functions. By selecting appropriate materials with good thermal conductivity for the support element, the design achieves effective thermal coupling without requiring additional thermal interface materials or complex thermal management structures
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 simple, cost-effective method for efficient heat sink coupling and cooling, reducing complexity and the need for additional components while maintaining mechanical and thermal performance.
Implementation Method 1
a heat sink (20), adapted to be mounted onto the free ends of the two prongs (162)
Implementation Method 2
facilitating cooling
Data Source
AI summary
According to the present disclosure, a lighting device is provided with a support member with a fork-like shape with two prongs carrying mutually facing electrically powered light radiation sources, and an annular heat sink member fitted onto the prongs and extending around the light radiation sources.