Sealed LED Lamp Assembly with Modular Heat Sink and Current Regulation
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Solution Overview
Problem
Solid-state light-emitting devices, such as LEDs, face challenges with efficiency and reliability due to sensitivity to temperature, require precise voltage control to prevent power surges, and need environmental protection from liquids and mechanical stress, while also needing to emit light efficiently and safely without causing eye damage.
Innovation Solution
A sealed LED lamp assembly is designed with a circuit board, heat sink, gasket, bezel, and fasteners to manage heat and provide mechanical and electrical protection, using a nonlinear resistive element like an incandescent lamp to regulate current and a bearing mount for individual rotational orientation of lamp assemblies to achieve uniform spectral characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple light-emitting devices are connected in series to achieve high power levels, then the total light output and voltage are proportional to the number of devices, but the complexity of the assembly and electrical connections increases
Solution Approach 1:
The patent divides the high-power illumination system into multiple modular lamp assemblies, each containing a series-connected string of light-emitting devices. Each module is independently packaged and sealed, allowing the system to achieve high total power through parallel connection of multiple standardized modules rather than creating a single complex assembly.
Solution Approach 2:
The patent implements a hierarchical structure where light-emitting devices are nested on a circuit board, which is nested within a sealed lamp assembly housing. Multiple such lamp assemblies are then nested within a common mounting structure, allowing scalable power output while maintaining modular simplicity at each level.
2Reliability
If a sealed structure is used to protect light-emitting devices from environmental factors, then reliability improves, but heat dissipation becomes more difficult
Solution Approach 1:
The patent introduces a thermally conductive epoxy or adhesive as an intermediary material between the light-emitting devices and the heat sink structure. This intermediary simultaneously provides mechanical bonding for sealing and thermal conduction for heat removal, resolving the conflict between sealed protection and heat dissipation.
Solution Approach 2:
The patent employs a sealed housing structure with integrated thermal pathways, where thin thermally conductive layers or coatings are applied to internal surfaces to conduct heat from the LED assemblies to external heat sinks, maintaining the sealed environment while enabling effective heat removal.
3Illumination intensity
If light-emitting devices operate at high power levels, then illumination intensity increases, but temperature sensitivity causes efficiency to drop and degradation rate to increase
Solution Approach 1:
The patent incorporates current regulation circuits that monitor and control the electrical current through each light-emitting device, preventing excessive current that would cause overheating and degradation. This feedback control maintains optimal operating conditions even as the system scales to high power levels.
Solution Approach 2:
The patent optimizes operating parameters such as forward current and junction temperature for each light-emitting device to maximize efficiency and minimize degradation. By carefully controlling these parameters and maintaining devices within their optimal operating ranges, the system achieves high illumination intensity while preserving reliability.
4Reliability
If precise voltage control is implemented to prevent power surges, then device reliability improves, but additional control circuits increase system complexity
Solution Approach 1:
The patent employs self-regulating electrical characteristics of the light-emitting devices and inherent current-limiting properties of the series connections to provide automatic protection against power surges. The system uses the devices' own electrical properties for regulation rather than requiring complex external control circuits.
Solution Approach 2:
The patent uses simple, robust current-limiting components such as resistors or fuse elements that provide adequate voltage control and protection without requiring complex active control circuits. These simple protective elements are easier to manufacture and more reliable than sophisticated regulation 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
The solution enhances the efficiency and reliability of LED lamp assemblies by maintaining stable operation, protecting against environmental factors, and ensuring safe and uniform light emission, effectively addressing the limitations of existing technologies.
Implementation Method 1
the remainder of the heat is removed through thermal conduction
Implementation Method 2
using a nonlinear resistive element like an incandescent lamp to regulate current
Implementation Method 3
solid-state light-emitting devices, the light-emitting diodes (LEDs)
Data Source
AI summary
A lamp assembly (1800) may include a circuit board (201), one or more light-emitting devices (100) disposed on the circuit board (201), a heat sink (600) in thermal contact with a surface of the circuit board (201), a gasket (700) with a first surface in mechanical contact with the circuit board (201), a bezel (800) a surface (805) of which is in mechanical contact with a second surface of the gasket (700), and one or more fasteners (901) that may apply a force between the bezel (800) and the heat sink (600). A lamp array (2100) may include two or more lamp assemblies (1800), not all of which supply illumination with the same spectral characteristic, and a bearing mount (2000) that may support each lamp assembly (1800) and allow each to be oriented rotationally. A supply circuit (2500, 2600) may include a nonlinear resistive element (2501, 2601).