Replaceable LED Board Assembly for Thermal-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 to ensure proper heat dissipation, then thermal management is improved, but replaceability deteriorates
Solution Approach 1:
The luminaire is divided into separable modules: the housing with integrated heat sink and the LED board with thermal paste. This segmentation allows the LED board to be removed and replaced while maintaining the thermal management function through the housing's heat sink structure that remains in place.
Solution Approach 2:
Thermal paste is introduced as an intermediary substance between the LED board and the housing heat sink. This thermal paste facilitates heat conduction from the LED board to the housing, enabling effective thermal management while allowing the LED board to be easily detached and replaced without permanent bonding.
2Ease of repair
If the LED board is made replaceable to reduce waste and cost, then ease of repair is improved, but thermal management deteriorates
Solution Approach 1:
By separating the LED board from the housing into distinct replaceable modules, the design enables easy replacement of the LED board while the housing's heat sink structure remains stationary to continue providing thermal management for subsequent LED boards.
Solution Approach 2:
The housing is pre-equipped with an integrated heat sink structure and thermal management features during manufacturing. This preliminary preparation ensures that when an LED board is replaced, the thermal management infrastructure is already in place and ready to handle the new LED board's heat dissipation requirements.
3Manufacturing precision
If alignment features are added to ensure consistent positioning, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
Alignment features such as asymmetric slots, protrusions, or keyed interfaces are incorporated into the LED board and housing. These asymmetric geometric features guide proper positioning and orientation during assembly, ensuring consistent alignment without requiring complex adjustment mechanisms.
Solution Approach 2:
The alignment features use simple geometric shapes like slots, holes, or protrusions that can be easily manufactured and assembled. These features create a straightforward copying and fitting relationship between the LED board and housing, ensuring precise positioning through simple geometric interlocking rather than complex positioning systems.
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 reducing waste by avoiding the need to replace the entire fixture.
Implementation Method 1
a 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 from the LED board to ambient surroundings
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. Methods of replacement of an LED board within a luminaire are also disclosed.