Sealed LED Light Module With Elastic Hermetic Seal
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Solution Overview
Problem
Existing LED light units face challenges in designing a sealed module that is cost-effective to manufacture in large volumes, while maintaining long-term stability and preventing dust, dirt, water, and humidity ingress, without compromising optical characteristics.
Innovation Solution
A sealed LED light module design featuring a heat-conducting metal base plate with laminated isolating and current-conducting structures, supported by a transparent cover with a sealing mechanism using semi-elastic plastic material for a hermetic seal, eliminating the need for screws or clips and allowing for automatic assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hermetic seal is implemented to prevent dust, dirt, water and humidity ingress, then reliability is improved, but device complexity increases due to the sealing mechanism
Solution Approach 1:
The sealing function is merged with the base plate and cover structures themselves. The sealing profile is integrated into the base plate, and the cover engages with this integrated sealing feature, eliminating the need for separate sealing components or complex sealing mechanisms.
Solution Approach 2:
A flexible sealing profile with elastic properties is used to create the hermetic seal. This elastic material can deform to accommodate thermal expansion differences between the base plate and cover while maintaining the seal, preventing contamination ingress without requiring complex adjustable sealing mechanisms.
2Ease of manufacture
If a screw-less connection is used to enable automatic assembly, then ease of manufacture is improved, but strength may be reduced compared to mechanical fasteners
Solution Approach 1:
The connection function is merged with the sealing function. The same sealing profile that creates the hermetic seal also provides the mechanical connection between the base plate and cover, eliminating the need for separate fastening elements like screws or clips.
Solution Approach 2:
The sealing material's elastic properties and the geometric design of the sealing profile create a strong mechanical connection. The engagement geometry and material properties are optimized to provide sufficient connection strength for automatic assembly processes without requiring additional fasteners.
3Illumination intensity
If the cover acts as a lens for guiding light, then optical functionality is improved, but manufacturing precision requirements increase
Solution Approach 1:
The cover is designed to perform multiple functions simultaneously: it provides the hermetic seal engagement, structural support for the base plate, and optical lens functionality for light guidance. This multi-functionality reduces the need for separate precision optical components.
Solution Approach 2:
The optical parameters of the cover (refractive index, surface curvature, thickness) are optimized to provide effective light guidance. By adjusting these parameters, the cover can function as an effective lens without requiring extremely tight manufacturing tolerances, as the material properties contribute to the optical 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
The solution provides a cost-effective, durable, and optically stable LED light unit that prevents contamination and thermal expansion issues, ensuring extended lifespan and improved quality by forming a watertight, screw-less connection between the base plate and cover.
Implementation Method 1
Due to the elastic properties of the seal, different thermal expansion of the base plate and the cover may be equalized, therefore preventing cracks or even bending of the unit at extreme temperatures.
Implementation Method 2
different thermal expansion of the base plate and the cover may be equalized
Implementation Method 3
the base plate is a heat conducting plate which may be made of a metal, like aluminum
Data Source
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AI summary
A sealed LED light module comprises a base plate (200), having at least one LED, and a cover (100) providing a base plate support (130, 131). The base plate (200) is located on the cover (10) to define an inner space (140) which is sealed against the environment. For sealing the cover (100) has at least one sidewall (110), which defines a trench (141) together with at least one base plate support (130, 131), and the trench (141) holds a sealing (300) which interacts with at least one edge (206, 207) of the base plate (200) and the surface of the trench (141) to seal the inner space (140) against the environment.