Lighting Module Heat Sink for Thermal Management

Solution Overview

Problem

Existing lighting modules fail to provide optimal cooling for light units in luminaires, limiting the use of more LEDs on a heat sink or driving LEDs at higher currents, which restricts lumen output and brightness, and do not offer effective thermal management for high-intensity light emission.

Innovation Solution

A lighting module with an elongated hollow tube heat sink having a fluid inlet and outlet, positioned between the driver unit and light unit, allowing for unobstructed fluid flow and separating the light and driver units for enhanced cooling, while also providing mechanical strength and compactness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If more LEDs are mounted on a heat sink or LEDs are driven at higher current to increase lumen output, then brightness and lumen output are improved, but thermal management becomes insufficient and light source lifetime decreases

Engineering Contradiction:

Core Design Contradiction:

Illumination intensityVSReliability

Solution Approach 1:

The heat sink is divided into two separate heat sink bodies, each with its own heat dissipation channels, allowing independent thermal management for the light source and driver circuit. This segmentation enables more effective heat removal from high-power LEDs without compromising reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A reflector is positioned between the light source and driver circuit to redirect light while also serving as a thermal management component. The reflector helps direct light output while the separated heat sink structures manage thermal loads, enabling higher current operation without reducing light source lifetime.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If a compact lighting module design is used, then space utilization is improved, but thermal management effectiveness may be compromised

Engineering Contradiction:

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

The lighting module uses vertical stacking arrangement where the light source, reflector, and driver circuit are positioned in different vertical levels. The first heat sink body is positioned below the light source while the second heat sink body is positioned above the driver circuit, creating three-dimensional thermal management within a compact footprint.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The reflector is nested within the housing structure and positioned between the light source and driver circuit, effectively utilizing the space between components for both optical and thermal management functions, thereby achieving compact design without compromising heat dissipation.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Device complexity

If the light source and driver circuit are positioned close together for compactness, then device complexity is reduced, but thermal interference between components increases

Engineering Contradiction:

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The heat sink system is segmented into two separate heat sink bodies with distinct heat dissipation channels. The first heat sink body is thermally coupled to the light source while the second heat sink body is thermally coupled to the driver circuit, preventing thermal interference despite close positioning of components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reflector serves as an intermediary component positioned between the light source and driver circuit. It redirects light while also acting as a thermal barrier, preventing heat from the light source from directly affecting the driver circuit and vice versa.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 configuration enables improved thermal management, allowing for increased LED usage or higher current driving, thereby enhancing both efficiency and the lifetime of the light source, while maintaining a compact and lightweight design.

Implementation Method 1

a heat sink configured for removing heat from the at least one solid state light source

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the heat sink comprises an elongated hollow tube extending in the direction of the longitudinal axis and comprising a fluid inlet and a fluid outlet

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS11022294B2Lighting module and a luminaire comprising the lighting modulespe

Publication Date: 2021.06.01

AI summary

The invention provides a lighting module (100) for use in a luminaire (200). The lighting module comprises a base (101) having a longitudinal axis (LA) which comprises an electrical connector (102) for connecting the lighting module (100) to a luminaire socket (201) of the luminaire (200). The lighting module (100) further comprises a driver unit (103) which comprises a driver circuit (104) which is electrically connected to the electrical connector (102). The lighting module (100) further comprises a light unit (105) which comprises at least one solid state light source (106) which is electrically connected to the driver circuit (104) and emits light. The lighting module (100) further comprises a heat sink (107) which removes heat from the at least one solid state light source (106). The heat sink (107) comprises an elongated hollow tube (108) which extends in the direction of the longitudinal axis (LA) and comprises a fluid inlet (109) and a fluid outlet (110), wherein the heat sink (107) is arranged between the driver unit (103) and the light unit (105).