Modular LED Holder for Luminaire Heat Sink Replacement
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Solution Overview
Problem
Conventional LED luminaires lack interchangeability and are difficult to maintain due to non-replaceable LED light sources affixed to heat sinks, which complicates changes in wattage or color temperature and poses risks during installation and replacement.
Innovation Solution
An LED holder system with a planar base member, substrate, and removable cover that allows for easy coupling and decoupling from a heat sink, featuring quick-release fasteners and electrical contacts for toolless wire connections, enabling the replacement of LED packages without disassembling the luminaire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional LEDs are affixed to heat sinks with double-sided tape or arctic silver, then the LED light source is securely attached, but removal and replacement becomes difficult requiring luminaire disassembly
Solution Approach 1:
The LED assembly is segmented into separate components: the LED module, the heat sink, and the mounting bracket. This allows the LED module to be independently removed and replaced without disassembling the entire luminaire, resolving the contradiction between secure attachment and ease of replacement.
Solution Approach 2:
A mounting bracket serves as an intermediary component between the LED module and the heat sink. The bracket provides a standardized interface with quick-release fasteners that enable easy attachment and detachment of the LED module while maintaining secure mounting, thus facilitating both strong attachment and easy replacement.
2Stability of the object's composition
If LED light sources are permanently affixed to heat sinks, then structural stability is maintained, but adaptability for changing wattage or color temperature is lost
Solution Approach 1:
The mounting system transitions from a static permanent attachment to a dynamic reversible connection using quick-release fasteners. This allows the LED module to be easily detached and reattached, enabling users to change wattage or color temperature by simply replacing the module while maintaining structural stability during operation.
3Volume of moving object
If conventional LED chip packages are used, then manufacturing compactness is achieved, but the fragile nature makes them subject to damage during manufacturing, packaging, shipping, and installation
Solution Approach 1:
The LED chip package is segmented into a modular assembly that includes protective elements and a standardized mounting interface. This modular design allows for better protection during handling while maintaining compactness, and enables easy replacement if damage occurs, thus improving reliability without sacrificing compactness.
4Volume of moving object
If LED chip packages are used, then space efficiency is improved, but electrostatic discharge damage during installation and replacement becomes a risk
Solution Approach 1:
An intermediary mounting bracket with standardized electrical contacts serves as a protective interface between the LED module and the luminaire's electrical system. This intermediary structure provides electrostatic discharge protection and facilitates safe installation and replacement while maintaining space efficiency through compact modular design.
Data Source
AI summary
A LED holder includes a planar base member to releasably couple the holder to the heat sink of a luminaire. The LED holder also includes a substrate that is coupled to the planar base member and has one or more LEDs disposed on the substrate and electrically coupled to the substrate. The substrate can be a printed circuit board and the LEDs can be discrete LEDs or an LED package. A cover panel is removably coupled to the planar base member and is designed to prevent access to the substrate and the LEDs when the luminaire powered on. The LED holder can also include a LED cover positioned over the LEDs and within the cover panel to limit access to the top side of the LEDs while permitting light emitted by the LEDs to pass through the LED cover.