Lighting Device Segmented Heat Sink Assembly

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional lighting devices have a lifespan dependent on both the light source and circuitry, making it difficult to replace damaged components independently and leading to increased manufacturing costs and defects due to complex assembly processes.

Innovation Solution

A lighting device design where the light source and circuitry are separable, with a heat sink fastened using a hook to prevent tampering and an inlet for injecting molding liquid directly into heat-generating parts, reducing manufacturing costs and assembly time by eliminating unnecessary components and simplifying the assembly process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the light source and circuitry are integrated in a single housing, then the structure is simplified and assembly is easier, but the lifespan of the lighting device becomes dependent on both components and replacement of damaged parts is difficult

Engineering Contradiction:

Improvestructure complexityVSAvoidcomponent replacement ease

Core Design Contradiction:

Device complexityVSEase of repair

Solution Approach 1:

The lighting device is divided into two separable modules: a light source module containing the light emitting element and a circuitry module containing the power supply and control circuitry. Each module has its own housing and can be independently replaced, allowing the lifespan of the device to be extended by replacing only the failed component rather than the entire assembly.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If conventional bolt fastening is used to secure the power supply unit housing, then the structure is simple, but defects occur due to destruction of the tap and cracking

Engineering Contradiction:

Improveassembly simplicityVSAvoiddefect rate

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The fastening system is segmented into multiple attachment points distributed around the housing perimeter, replacing a single central bolt connection. This distributes mechanical stress and prevents concentration of force that causes tap destruction and cracking in conventional designs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mechanical bolt fastening system is replaced with a snap-fit or clip-based mechanical interlocking system. The circuitry housing includes protrusions that engage with corresponding recesses in the light source housing, providing secure attachment without the need for threads that can be destroyed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Object-affected harmful factors

If a rubber cover is added to prevent water leakage during molding liquid injection, then sealing is improved, but manufacturing cost increases due to additional components

Engineering Contradiction:

Improvewater leakage preventionVSAvoidmanufacturing cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The rubber cover component is completely removed from the design. Instead, the housing itself is designed with integrated sealing features including raised rims and groove structures that create liquid-tight barriers during the molding injection process, eliminating the need for separate sealing components.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The sealing function is merged into the housing structure itself rather than being a separate component. The circuitry housing includes integrated sealing ribs and grooves that work with the light source housing to prevent water leakage during molding, combining the structural and sealing functions into a single piece.

Inventive Principle:

Principle #5Merging (Combining)

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

Enables independent replacement of light sources and circuitry, reduces defects, and lowers manufacturing costs by simplifying the assembly process and reducing the need for additional components like rubber covers, while maintaining security through the hook-fastened design.

Implementation Method 1

a heat sink including: a first receiver in which the second placement portion of the member is disposed

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

an inlet for injecting molding liquid to an inner case and causes the molding liquid to be injected into only heat generating parts

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Data Source

PatentEP3179152B1Lighting device

Publication Date: 2020.03.18 LG INNOTEK CO LTD

Figure 1
Figure 2
Figure 3~4

AI summary

A lighting device may be provided that includes: a light source including: a member which includes a first placement portion and a second placement portion; a light source module which is disposed in the first placement portion; and a first terminal which is disposed in the second placement portion and is electrically connected to the light source module; and a heat sink including: a first receiver in which the second placement portion of the member is disposed; a second receiver in which a circuitry is disposed; and a second terminal which is disposed corresponding to the first terminal of the light source.