Recessed Light Fixture With Internal Heat Sink And Removable LED Module
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Solution Overview
Problem
Existing recessed lighting fixtures with small aperture formats face challenges in dissipating heat effectively, requiring large ceiling alterations for LED replacement and maintenance, and lack a serviceable design that allows for component replacement without damaging the ceiling.
Innovation Solution
A recessed light fixture design with a removable LED light engine assembly and heat sink, utilizing a mechanical connector and thermal interface that allows for insertion and removal through a small ceiling opening, enabling service without altering the ceiling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a one-piece light fixture design is used, then heat dissipation is improved, but ease of repair deteriorates
Solution Approach 1:
The light fixture is divided into separate modular components: a trim assembly that remains fixed in the ceiling and a light engine assembly that can be removed and replaced. This segmentation allows the heat sink to remain in place for continuous heat dissipation while the LED module can be independently serviced through the same small ceiling opening used during installation.
2Ease of operation
If a small aperture format is used, then ease of operation is improved, but heat dissipation deteriorates
Solution Approach 1:
The heat dissipation solution extends into the third dimension by allowing the heat sink to protrude above the ceiling surface. This vertical dimension provides sufficient surface area for heat dissipation while maintaining a minimal ceiling opening for installation and servicing. The trim assembly covers the opening while the heat sink operates in the space above the ceiling.
3Ease of repair
If a serviceable design is used, then ease of repair is improved, but device complexity deteriorates
Solution Approach 1:
The mechanical connector integrates multiple functions into a single component interface: it provides structural support, electrical connectivity, and thermal coupling between the light engine assembly and the trim assembly. This merging of functions reduces the number of separate components and simplifies the overall design while maintaining serviceability through the removable light engine assembly.
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
Facilitates LED replacement and maintenance by allowing components to be serviced through a minimal ceiling opening, maintaining the integrity of the ceiling and eliminating the need for large diameter trims.
Implementation Method 1
a heat sink connected to the enclosure with a thermal interface... the base can a thermal interface adapted for thermal coupling to the thermal interface of the heat sink
Implementation Method 2
For high output light assemblies and luminaries, a way must be provided to dissipate heat generated in creating the light
Implementation Method 3
A mechanical connector which is disposed within the enclosure and is connected to the heat sink, and is adapted to removably connect the base of the light engine assembly to the heat sink
Data Source
AI summary
A recessed light fixture has a heat sink and a removable light engine assembly. A thermally conductive base of the light engine assembly has an LED and has a thermal interface adapted for thermal coupling to a thermal interface of the heat sink. A mechanical connector in the enclosure can connect the base of the light engine assembly to the heat sink and couple the thermal interfaces of the light engine assembly and heat sink. The base of the light engine assembly is insertable through an opening in the ceiling aligned and can be urged into connected and disconnected states, from within the room, with a minimal clearance between the opening in the ceiling and the base, whereby the light engine assembly can be replaced or serviced from within the room without disturbing the ceiling and without the use of a large diameter trim.