Panel Light Heat Sink Plugging Structure
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Solution Overview
Problem
Conventional lighting devices, such as downlights, face challenges in installation convenience, safety, and cost due to their design and component complexity, which affects manufacturing and storage costs, and there is a need for innovative solutions that simplify installation and assembly while enhancing performance.
Innovation Solution
A panel light apparatus with a heat sink frame, LED light bar, optical guiding module, and back cover design that allows for easy assembly and installation, featuring a heat sink frame with plugging structures for both structural and electrical connections, an optical guiding module with a light diffusion and guiding layer for softening light output, and a driver box with pre-installed electrical components for efficient power conversion and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional downlight devices are designed with sufficient installation cavity space, then heat dissipation and component placement are improved, but installation complexity and time increase
Solution Approach 1:
The device is divided into modular components including a driver module, LED light source module, and optical module that can be independently manufactured and assembled. This segmentation allows each component to be optimized separately while simplifying the overall installation process, as the modular units can be pre-assembled and tested before final installation.
Solution Approach 2:
The heat sink structure serves multiple functions: it provides mechanical support for mounting components, acts as a thermal management system through its heat dissipation design, and forms part of the optical path structure. This multi-functionality reduces the number of separate components needed, thereby simplifying installation while maintaining effective heat dissipation.
2Reliability
If downlight devices use complex component assemblies, then performance and reliability are improved, but manufacturing and storage costs increase
Solution Approach 1:
Critical sub-assemblies such as the driver module and LED light source module are pre-assembled and pre-tested during manufacturing. This preliminary action ensures quality control and reliability while reducing on-site installation complexity and potential errors, ultimately lowering overall manufacturing and installation costs.
Solution Approach 2:
Multiple functions are combined into integrated modules: the driver module integrates power conversion and control circuitry, while the optical module combines light guiding and diffusion elements. This merging reduces the total number of separate components, simplifying both manufacturing processes and storage requirements while maintaining system reliability.
3Ease of operation
If panel light apparatus uses thin design without additional installation cavity, then installation convenience is improved, but heat dissipation capability deteriorates
Solution Approach 1:
The heat dissipation strategy transitions from relying on installation cavity volume to utilizing the lateral surface area of the heat sink. The heat sink features extended fins and surface structures that increase the effective heat dissipation area in the plane of the panel, enabling efficient thermal management in a thin profile without requiring additional installation cavity space.
Solution Approach 2:
The heat sink structure incorporates locally optimized features such as increased fin density in high-heat-generation areas, variable thickness regions for thermal management, and strategically placed mounting points. This local quality optimization ensures effective heat dissipation throughout the thin panel structure without compromising installation convenience.
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 solution provides a cost-effective, easy-to-install, and safe panel light apparatus with improved light distribution and reduced heat generation, enhancing user safety and manufacturer convenience by eliminating the need for additional installation cavities and simplifying assembly processes.
Implementation Method 1
a light guiding layer having a lateral side facing to LED modules of the first LED light bar for guiding light of the LED modules to the diffusion layer via the light guiding layer and then to escape from a front side of the optical guiding module
Implementation Method 2
The light diffusion layer is used for diffusing light so that the light would not look too hash for human eyes, e.g. to soften the output light and to avoid users see a series of strong light points
Implementation Method 3
The first LED light bar is a major heat source, and heat generated from the first LED light bar is transmitted to the frame bars of the heat sink frame
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A panel light apparatus includes a heat sink frame (11), a first LED light bar, an optical guiding module (13) and a back cover (28). The first LED light bar has a first plugging structure (312, 313, 314, 315) to be plugged to a second plugging structure of the heat sink frame (11). Heat of the LED light bar is transmitted to the heat sink frame (11). The optical guiding module (13) includes a light diffusion layer (231) and a light guiding layer (232). A lateral side of the light guiding layer (232) faces to LED modules of the first LED light bar for guiding light of the LED modules to the diffusion layer. The light guiding layer (232) and the light diffusion layer (231) are fixed together as an assembly module before being placed in the surrounding border.