Mica-Based LED Holder for Thermal Stability and Shadowing
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Solution Overview
Problem
LED holders made from thermoplastic materials lose mechanical stability at high temperatures, leading to inadequate pressure on heat sinks and reduced cooling efficiency, which shortens the service life of LEDs and creates shadowing issues due to large housing dimensions for power connections.
Innovation Solution
A flat LED holder constructed from thermally stable mica-based insulating material, comprising multiple plates with masks for precise positioning and light passage, ensuring reliable pressure on the heat sink and efficient cooling, using screws and rivets for secure attachment and conductive contacts for power supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If LED holders are made from thermoplastic materials, then manufacturing cost and ease of manufacture are improved, but mechanical stability is lost at high temperatures leading to reduced cooling efficiency
Solution Approach 1:
The LED holder is constructed from a composite material consisting of a thermally stable mica-based insulating material that maintains mechanical stability at high temperatures while providing electrical insulation. This composite material replaces conventional thermoplastic materials, resolving the contradiction between ease of manufacture and mechanical stability under thermal stress.
2Device complexity
If conventional thermoplastic LED holders are used, then manufacturing simplicity is improved, but pressure on heat sink decreases at high temperatures reducing cooling effect
Solution Approach 1:
The invention changes the material parameters of the LED holder by using a mica-based insulating material with high thermal stability. This material maintains its mechanical properties and dimensional stability at elevated temperatures, ensuring consistent pressure on the heat sink and reliable cooling performance throughout the LED's service life.
3Ease of operation
If large housing dimensions are used for power connection terminals, then ease of connection is improved, but shadowing occurs in the emitting area of flat LEDs
Solution Approach 1:
The invention transitions from conventional three-dimensional housing structures to a flat, plate-like LED holder design. This dimensional change allows power connection terminals to be integrated into the flat structure without protruding beyond the LED's emitting area, eliminating shadowing while maintaining connection functionality through surface-mounted or edge-mounted terminal configurations.
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
Maintains mechanical stability under high thermal stress, ensures consistent pressure on the heat sink, enhances cooling, and minimizes housing size to prevent shadowing, thereby extending the service life and improving the LED holder's performance.
Implementation Method 1
The LED holder is a flat unit and constructed in the form of plates, each plate consisting of a thermally stable mica-based insulating material
Implementation Method 2
In addition, a spring element 11 is provided, which exerts a spring force on the conductive contacts 8, 9 in order to ensure a reliable contact
Data Source
Figure 1
Figure 2
Figure 3a~4
AI summary
The invention relates to LED holders (1) with leads (4) for a power connection. The LED (2) contacts a heat sink (3) for heat dissipation. According to the invention, the LED holder (1) consists of a thermally stable insulating material, which primarily contains minerals. The LED holder (1) is structurally flat and plate-shaped. The LED (2) is mounted on a carrier (10), which in turn can be attached to the heat sink (3) via the LED holder (1). The plate-shaped LED holder (1) has two or more plates (6, 7), each with a mask (16, 17) that are adapted to the shape of the carrier (10) for reliable positioning (Fig. 1).