Prismatic LED Module with Downward Heat Sink
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Solution Overview
Problem
Conventional LED luminaire designs face challenges in efficiently directing and shaping light to achieve desired illumination patterns and heat management, particularly in ensuring effective heat dissipation and optimal light distribution.
Innovation Solution
The LED module features a downwardly directed heat sink with cooling fins and a catadioptric prism that mounts over the LEDs, allowing for acute angle installation on a luminaire carrier plate, which shapes and directs light while providing efficient heat dissipation through anodized die-cast aluminum construction and thermal paste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional LED modules use upwardly directed heat sinks mounting on the carrier plate, then the modules can be easily installed, but the light distribution pattern cannot achieve desired illumination and heat management efficiency
Solution Approach 1:
The patent inverts the conventional mounting orientation by directing the heat sink downward and mounting the module on the underside of the carrier plate. This inversion allows the light to be projected upward through the carrier plate, achieving the desired illumination pattern while maintaining effective heat dissipation through the downward-directed heat sink with cooling fins.
2Temperature
If LED modules use standard heat sink designs, then manufacturing is simplified, but heat dissipation efficiency is insufficient for optimal LED operation
Solution Approach 1:
The heat sink is segmented into multiple cooling fins extending downward from the top wall, increasing the surface area for heat dissipation. This segmented design efficiently transfers heat from the LED-mounted front face through the heat sink structure to the ambient air, maintaining optimal LED operating temperatures.
Solution Approach 2:
The heat sink utilizes the vertical dimension by extending cooling fins downward from the top wall, creating a three-dimensional heat dissipation structure. This dimensional approach maximizes heat transfer surface area within the available space, improving thermal management efficiency.
3Illumination intensity
If simple reflectors are used to direct light, then device complexity is reduced, but the ability to shape and direct light for specific illumination patterns is limited
Solution Approach 1:
The patent replaces conventional mechanical reflectors with a catadioptric prism that uses optical refraction and internal reflection surfaces to shape and direct light. The prism's precisely engineered surfaces provide superior control over light distribution patterns while maintaining a compact structure.
4Illumination intensity
If LED modules are mounted with vertical orientation, then installation is straightforward, but dark spots below the luminaire cannot be filled
Solution Approach 1:
By inverting the mounting orientation to attach modules on the underside of the carrier plate with downward-directed heat sinks, the light is projected upward through the carrier plate. This inversion eliminates dark spots below the luminaire by ensuring uniform light distribution across the illuminated area.
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 configuration enables the production of specific light beam patterns compliant with IES NEMA regulations and effective heat management, ensuring high light intensity distribution with minimal vertical and horizontal spread, filling dark spots below the luminaire.
Implementation Method 1
a plurality of cooling fins extending rearward from the front end and downward from the top wall
Implementation Method 2
anodized die-cast aluminum construction and thermal paste
Implementation Method 3
a catadioptric prism that mounts over the LEDs, which shapes and directs light
Implementation Method 4
catadioptric prism...shapes and directs light...compliant with IES NEMA regulations
Implementation Method 5
anodized die-cast aluminum construction and thermal paste
Data Source
AI summary
An LED module for a luminaire has a downwardly directed heat sink comprising cooling fins that extend rearward from the module's front end and downward from its top wall, which has a top face that abuts the underside of a luminaire carrier plate. A circuit board carrying at least one LED is mounted on the front face, and a prism is mounted to the heat sink over the LED(s). The front (light-emitting) face of the catadioptric prism has several prominent side-by-side sections which emit beam patterns that diverge laterally and overlap in a central region. A prominent full-width upper section on the front face emits a primarily downwardly directed beam pattern to help fill in dark spots.