Light-emitting Module with Elastic Cushion for Thermal Stability
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Solution Overview
Problem
Existing light-emitting modules face challenges in achieving high heat dissipation and precision assembly due to the lack of effective thermal management and alignment between the light-emitting element and the fixing base, particularly in applications requiring small size and high luminous intensity, such as automotive headlights.
Innovation Solution
A light-emitting module design incorporating a first mounting board with a recess and an elastic cushion between the light-emitting element and the fixing base, allowing for elastic deformation and improved contact, thereby enhancing thermal conductivity and tolerance for assembly precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rigid mounting structure is used to ensure precise alignment between the light-emitting element and the fixing base, then assembly precision is improved, but the tolerance for manufacturing variations is reduced and heat dissipation is compromised
Solution Approach 1:
The patent changes the physical state of the mounting structure from rigid to elastic by introducing an elastic cushion. This allows the structure to deform and adapt to manufacturing variations, simultaneously achieving precise alignment and stable heat dissipation. The elastic cushion's ability to change its deformation parameter enables it to compensate for dimensional tolerances while maintaining thermal contact.
Solution Approach 2:
The elastic cushion acts as an intermediary element between the first mounting board and the second mounting board. It mediates the connection by providing both mechanical support and thermal conduction while accommodating alignment variations. The cushion's elastic properties allow it to adapt to positional deviations, ensuring reliable contact without requiring high assembly precision.
2Stability of the object's composition
If the second mounting board is fixed rigidly to the first mounting board, then structural stability is improved, but the ability to compensate for assembly errors is reduced
Solution Approach 1:
The patent introduces dynamics into the mounting structure by using an elastic cushion instead of a rigid fixed connection. The cushion can dynamically deform to accommodate assembly errors while maintaining structural stability. This dynamic adaptation allows the system to absorb dimensional variations and positioning deviations without compromising overall stability.
Solution Approach 2:
The elastic cushion provides beforehand cushioning by being pre-installed between the mounting boards with sufficient thickness to accommodate expected assembly variations. This prior cushioning ensures that even if assembly errors occur, the cushion can deform to maintain contact and functionality, preventing misalignment issues.
3Adaptability or versatility
If a thick elastic cushion is used to increase tolerance for assembly precision, then adaptability is improved, but the thermal conduction path is lengthened and heat dissipation efficiency is reduced
Solution Approach 1:
The patent optimizes the thickness parameter of the elastic cushion to achieve a balance between adaptability and thermal conduction. By carefully selecting the cushion thickness, it provides sufficient deformation capacity for assembly tolerance while maintaining an efficient thermal conduction path. The cushion's material properties and dimensions are tuned to ensure both mechanical compliance and thermal performance.
4Temperature
If the light-emitting element is mounted directly without an elastic cushion, then the thermal conduction path is shortened and heat dissipation is improved, but the tolerance for assembly errors is reduced
Solution Approach 1:
The patent changes the mounting approach from direct rigid mounting to elastic cushion-mounted positioning. This parameter change allows the system to achieve both good heat dissipation and high alignment tolerance. The cushion's elastic properties enable it to compensate for positioning errors while maintaining sufficient thermal contact between the light-emitting element and the heat dissipation path.
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
The design achieves high heat dissipation performance with a 4.2% lower junction temperature compared to modules without the cushion, stabilizing heat dissipation and ensuring reliable operation across varying assembly conditions.
Implementation Method 1
an elastic cushion between the light-emitting element and the fixing base, allowing for elastic deformation and improved contact
Implementation Method 2
The light-emitting element is provided on the light-emitting element surface of the second mounting board and configured to emit light through the opening
Data Source
AI summary
A light-emitting module includes a first mounting board having a first surface and a second surface opposite to the first surface. The first mounting board has a recess on the first surface, and the recess has a bottom surface. The first mounting board has an opening passing through the first mounting board from the bottom surface to the second surface. The light-emitting module further includes a second mounting board provided in the recess, a light-emitting element provided on the second mounting board and configured to emit light through the opening, and an elastic cushion provided between the first mounting board and the second mounting board. The light-emitting module also includes a connector. The connector and the opening sandwich a center of the first mounting board when viewed from a direction from the second surface to the first surface.