Light Module Housing Electrical Connection Heat Dissipation
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Solution Overview
Problem
Conventional LED modules lack effective heat dissipation and operational support through their power supply connections, which limits their efficiency and lifespan.
Innovation Solution
The integration of a housing-based electrical connection system where the outer line forms a heat-conducting surface with the housing and the inner line contacts the base, allowing for efficient heat dissipation, combined with additional features like heat-conducting materials, insulating fillers, and a coaxial control line for enhanced cooling and control functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional separately designed plug connection is used for power supply, then the electrical connection is simple to implement, but heat dissipation efficiency is poor
Solution Approach 1:
The patent merges the electrical connection function with the housing structure by making the outer line of the electrical connection form an outer surface of the housing. This integration allows the housing to serve dual purposes: structural protection and heat dissipation, while providing electrical connection functionality. The housing itself becomes part of the electrical connection system, eliminating the need for separate complex plug structures.
Solution Approach 2:
The housing is designed to perform multiple functions simultaneously: it provides structural enclosure, serves as a heat dissipation path through its heat-conducting material, acts as an electrical connection component (outer line), and potentially functions as a reflector for light distribution. This multi-functionality resolves the contradiction by making the existing housing structure serve additional purposes without proportionally increasing complexity.
2Temperature
If the outer line is formed by the housing and inner line contacts the base, then heat dissipation is improved, but manufacturing precision requirements increase
Solution Approach 1:
By making the outer line form the housing itself rather than a separate component, the patent eliminates alignment issues between separate outer line and housing parts. The housing structure inherently defines the outer line position, reducing manufacturing precision requirements for electrical connection alignment.
3Temperature
If heat-conducting materials are used for outer line and inner line, then heat dissipation efficiency increases, but material selection and cost complexity increase
Solution Approach 1:
The housing, already present as a structural component, is specified to be made of heat-conducting material. This allows the same material to serve both structural and thermal management functions, avoiding the need for additional specialized heat-conducting components and simplifying material selection and manufacturing.
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 enables improved heat management and operational efficiency, increasing the light module's lifespan and performance by effectively dissipating heat generated by the LEDs and allowing for flexible control of light output.
Implementation Method 1
an outer line of the electrical connection is formed by the housing and an inner line or a center line of the electrical connection contacts the base
Implementation Method 2
an electrically-insulating filler material may be present between the outer line and the inner line
Implementation Method 3
the housing may form a reflector, which reflects the light outward from the at least one light source
Data Source
AI summary
A light module has at least one light source mounted on a base, especially an LED, a housing to accommodate the base, an electrical connection element for power supply of at least one light source. An outer line of the connection element is formed by the housing, and an inner line, especially center line, of the connection element, which is at least partially enclosed by the outer line, contacts the base.