Replaceable LED Board Assembly for Thermally Managed Luminaires
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Solution Overview
Problem
Existing luminaires with LED boards are not designed to be replaceable due to thermal considerations, leading to the entire fixture being discarded when the LED board fails, which is costly and inefficient.
Innovation Solution
A luminaire design with a removable and replaceable LED board featuring alignment and attachment elements, a detachable electrical coupling, and alignment features to ensure consistent positioning, allowing easy replacement and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the LED board is permanently affixed to the housing with thermal paste to ensure adequate heat dissipation, then thermal management is improved, but the LED board becomes non-replaceable and the entire fixture must be discarded when the LED board fails
Solution Approach 1:
The patent divides the luminaire into separable modules: a replaceable LED board module and a housing with heat sink. The LED board is designed as a distinct, removable component that can be replaced independently without replacing the entire fixture or compromising the heat dissipation system.
Solution Approach 2:
The patent introduces an intermediary thermal interface system consisting of thermal paste applied to the housing heat sink surface and a removable thermally conductive layer on the LED board. This intermediary system maintains effective thermal contact when the LED board is installed while allowing easy removal and replacement.
2Ease of repair
If the LED board is designed to be replaceable without precise thermal contact, then ease of repair is improved, but heat dissipation becomes inadequate and LED board life is shortened
Solution Approach 1:
The patent applies thermal paste to the housing heat sink surface during manufacturing as a preliminary action. This ensures that when a replacement LED board is installed, the thermal interface is already prepared, eliminating the need for precise manual application during field replacement while maintaining reliable thermal contact.
Solution Approach 2:
The patent changes the thermal interface parameters by using a removable thermally conductive layer on the LED board that can be easily applied and removed. This layer provides consistent thermal contact properties without requiring precise manual application, maintaining reliable heat dissipation while enabling easy replacement.
3Device complexity
If the entire fixture is discarded when the LED board fails, then manufacturing simplicity is maintained, but cost-effectiveness and resource efficiency are reduced
Solution Approach 1:
The patent segments the luminaire into replaceable LED board modules and a permanent housing with heat sink. This segmentation allows the valuable housing, heat sink, and other components to be retained and reused, discarding only the failed LED board module, thereby reducing material waste while maintaining design simplicity.
Solution Approach 2:
The patent enables discarding only the failed LED board while recovering and reusing the housing, heat sink, and other permanent components. This approach reduces material waste and resource consumption while maintaining the simplicity of the overall fixture design.
4Temperature
If thermal paste is precisely applied and the LED board is precisely assembled to ensure adequate thermally conductive contact, then heat dissipation is improved, but the complexity and skill required for installation increases
Solution Approach 1:
The patent applies thermal paste to the housing heat sink surface during manufacturing as a preliminary action. This eliminates the need for field technicians to perform precise thermal paste application, reducing installation complexity and skill requirements while maintaining effective heat dissipation.
Solution Approach 2:
The patent designs the LED board with a removable thermally conductive layer that self-aligns and self-adjusts to the housing heat sink surface when installed. This self-service mechanism ensures adequate thermal contact without requiring precise manual positioning or application skills, simplifying installation while maintaining heat dissipation performance.
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
Enables cost-effective maintenance by allowing individual LED board replacement, extending the luminaire's lifespan and ensuring safe, efficient thermal dissipation.
Implementation Method 1
a removable and replaceable LED board configured to be installed in the housing... thermal considerations... thermal paste or other heat-conductive material is applied to the back of an LED board to help dissipate the heat by conduction to the housing as a heat sink
Data Source
AI summary
A removable LED board and a luminaire incorporating a replaceable LED board are disclosed. The removable LED board comprises one or more LED light sources, one or more alignment and attachment elements configured for cooperative engagement with corresponding elements of the luminaire base or housing, and an electric connector. The luminaire also includes a lens cover which can function as an electrical fail-safe mechanism for the removable LED board. Methods of replacement of an LED board within a luminaire are also disclosed.