Modular Cooling Member for LED Lamp Heat Dissipation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing LED lamps with passive cooling systems face challenges in incorporating electronic driver circuits due to space constraints and material inefficiencies, particularly when emulating incandescent lamp shapes, which complicates manufacturing and heat dissipation.
Innovation Solution
A modular cooling member composed of multiple parts with a shared mounting cavity allows for easier integration and flexibility in design, enabling the use of thermally conductive materials and efficient heat transfer, while minimizing material consumption and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a one-piece cooling member is used to maintain rotational symmetry for incandescent lamp emulation, then the external shape and appearance are preserved, but the mounting cavity for electronic driver circuits becomes restricted and material consumption increases
Solution Approach 1:
The cooling member is divided into multiple separate parts (first cooling member part and second cooling member part) that can be assembled together. This segmentation allows the mounting cavity to have a more optimized shape for accommodating electronic driver circuits while maintaining the overall rotational symmetry of the external shape, and reduces material consumption by eliminating unnecessary solid construction in the cavity region.
2Ease of manufacture
If the mounting cavity is designed with straight edges for manufacturing simplicity, then production is easier, but the control electronics unit cannot be easily inserted and design flexibility is restricted
Solution Approach 1:
By dividing the cooling member into multiple assembleable parts, the mounting cavity can be designed with optimized shapes (including curved edges) that facilitate easy insertion of control electronics units, while each individual part remains manufacturable using standard processes like injection molding.
Solution Approach 2:
The control electronics unit is designed to be nested within the mounting cavity formed by the assembled cooling member parts. The cavity shape is optimized to accommodate the electronics unit, allowing easy insertion while the entire assembly maintains the rotational symmetry needed for incandescent lamp emulation.
3Reliability
If cables are routed through small holes in the cooling member, then electrical connections are established, but manufacturing resource requirements increase and the process becomes laborious
Solution Approach 1:
The segmented cooling member design allows cables to be routed more efficiently. The separate parts can be designed with integrated cable pathways or larger opening areas that facilitate easier cable routing during assembly, reducing the need for laborious manual routing through small holes while maintaining reliable electrical connections.
4Volume of moving object
If passive cooling members are designed to be compact, then space is saved, but heat dissipation effectiveness decreases and the cooling members become bulky when optimized for heat dissipation
Solution Approach 1:
The divided cooling member structure allows for optimized heat dissipation surfaces and internal pathways. The separate parts can be designed with enhanced cooling features (such as fins or heat sinks) on their external surfaces while maintaining a compact overall volume, improving heat dissipation effectiveness without increasing bulkiness.
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 simplifies the manufacturing and mounting of control electronics units, enhances heat transfer efficiency, and allows for a more compact, cost-effective LED lamp design that can effectively dissipate heat and maintain the appearance of incandescent lamps.
Implementation Method 1
The cooling member is composed of multiple cooling member parts, whereby each of which cooling member parts includes part of a wall of the mounting cavity... enhances heat transfer efficiency... effectively dissipate heat
Data Source
AI summary
A cooling member for at least one semiconductor light emitting element, in particular an LED, may include a mounting cavity for accommodating at least part of a control electronics unit, whereby the cooling member is composed of multiple cooling member parts, whereby each of which cooling member parts includes part of a wall of the mounting cavity.