Modular LED Units With Interlocking Heat Sinks
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Solution Overview
Problem
The development of lighting fixtures using LED modules is hindered by challenges such as heat dissipation, adaptability to varying light intensity, size, and placement requirements, leading to high costs and complexity in product development and assembly.
Innovation Solution
A modular LED unit design featuring interconnected heat sinks with lateral supports and side-fins for stable heat exchange and mounting, allowing for easy assembly and adaptation to different lighting applications, while reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If LED modules are used to replace HID lamps, then energy efficiency and lifespan are improved, but heat dissipation becomes a significant challenge
Solution Approach 1:
The lighting system is divided into modular LED units, each with its own heat sink. This segmentation allows heat to be distributed and dissipated at multiple locations rather than concentrated in a single point, effectively managing thermal load while maintaining energy efficiency
Solution Approach 2:
Heat sinks act as intermediary components between the LED modules and the environment. These heat sinks conduct heat away from the LED junctions and dissipate it through their extended surfaces, solving the heat dissipation problem without compromising the energy efficiency of the LED light sources
2Adaptability or versatility
If LED modules are adapted to varying lighting requirements, then versatility is improved, but product development costs increase
Solution Approach 1:
The modular LED unit design incorporates universal mounting features and standardized heat sink structures that can be adapted to various lighting applications. The heat sinks include mounting brackets and attachment mechanisms that work across different fixture types, allowing the same basic module to serve multiple functions and reducing the need for application-specific redesigns
Solution Approach 2:
The modular design allows for dynamic configuration where multiple identical units can be combined or arranged differently to meet varying lighting requirements. This dynamic adaptability through modular assembly rather than custom design reduces development costs while maintaining versatility
3Ease of operation
If modular LED units are designed for easy assembly, then ease of operation is improved, but structural stability may be compromised
Solution Approach 1:
The heat sink design merges the thermal management function with the mechanical mounting function. The mounting brackets are integrated directly into the heat sink structure, combining heat dissipation and structural support in a single component. This integration ensures structural stability while maintaining ease of assembly through the unified design
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
The modular LED unit facilitates efficient heat dissipation and easy assembly, enabling cost-effective and adaptable lighting solutions for various applications, including those previously served by HID lamps, by utilizing a stable and economical heat sink structure.
Implementation Method 1
a first heat sink (14) having a base (20) with a flat back surface (23)... adapted to receive one of the LED modules (12) against the module-engaging base surface... first and second lateral supports (60A, 60B) projecting from the back surface (23)... slidably supporting one of the LED modules (12) against the back surface (23) of the base (20)
Implementation Method 2
a plurality of inner-fins (30) projecting from an opposite surface (24) of the base (20)... first and second side-fins (40, 50), each projecting from the opposite surface (24) of the base (20)
Data Source
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AI summary
A modular LED unit (10) having a number of LED modules (12) separately mounted on individual interconnected preferably-extruded heat sinks (14), each heat sink having: a base (20) configured to engage and hold an LED module (12) in place and, in preferred forms, to facilitate the ganging of heat-sink/LED modules; and a plurality of fins, including inner-fins (30) and side-fins (40,50), projecting from the opposite surface (24) of the base (20) and extending therealong, the side-fins (40,50) having interlocking features to facilitate the ganging of heat-sink/module units together and, in preferred forms, to facilitate interconnection of the modular LED unit to other portions of a lighting fixture.