Miniature SMD-HPLED Lamp Heat Dissipation and Connector Design
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Solution Overview
Problem
Existing miniature SMD-LED lamps lack effective heat dissipation and efficient power connector design, limiting their size and functionality, particularly for high-power LEDs, and do not allow for a flush mounting of the LED source on the PCB, which restricts the lamp's miniaturization and heat management capabilities.
Innovation Solution
A miniature SMD-HPLED lamp design featuring a ceramic or metallic main body with a rectangular slot and groove configuration that houses the LED and power connectors, allowing for efficient heat dissipation and flush mounting, using a C-shaped metal band connector that provides both power and locking functionality, and supports various electrical standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a groove is used to house the electrical connector, then the connector is protected and organized, but the heat dissipation surface area is reduced
Solution Approach 1:
The electrical connector is repositioned from a horizontal groove configuration to a vertical arrangement, allowing the connector to extend through the lamp body. This dimensional change enables the connector to occupy the vertical space rather than horizontal space, thereby maximizing the lateral surface area available for heat dissipation while still providing protected housing for the connector elements.
2Reliability
If the LED source is mounted on a PCB with electrical connectors, then the electrical connection is reliable, but the mounting height increases preventing flush mounting
Solution Approach 1:
The electrical connector elements are extracted from the traditional PCB assembly and repositioned to engage directly with the LED source leads. This extraction allows the PCB to be positioned flush against the lamp body surface, while the connector elements extend vertically to provide reliable electrical connection without adding to the mounting height profile.
Solution Approach 2:
The electrical connector elements are nested within the lamp body structure, with the connector housing integrated into the lamp body and the connector elements extending through predetermined openings. This nesting arrangement allows the PCB and connector assembly to be compact, enabling flush mounting while maintaining reliable electrical connections.
3Temperature
If the lamp body material is ceramic, then heat dissipation and electrical insulation are improved, but manufacturing precision and surface finish are reduced
Solution Approach 1:
The lamp body employs a composite construction combining ceramic material for the main body to maximize heat dissipation and electrical insulation properties, with metallic or coated components for the electrical connector housing and mounting surfaces where precision and surface finish are critical. This composite approach allows each material to be used where its properties are most beneficial.
4Reliability
If the electrical connector is designed for power supply, then electrical connection is established, but the locking function is insufficient
Solution Approach 1:
The electrical connector is designed to combine both electrical connection and mechanical locking functions in a single integrated structure. The connector elements serve dual purposes: establishing electrical contact with the LED source leads while simultaneously providing mechanical retention through engagement with corresponding features in the lamp body, eliminating the need for separate locking mechanisms.
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 design enables a compact, high-power LED lamp with improved heat dissipation and reliable electrical connections, allowing for efficient power supply and secure locking of the LED, while maintaining a flush mounting configuration for optimal light beam utilization.
Implementation Method 1
A miniature SMD-HPLED replaceable lamp (10) is constituted by a ceramic or metallic main body (1), a SMD-HPLED (3) and a electric connector (20)... C-shaped metal band connector that provides both power and locking functionality
Implementation Method 2
The same lamp is used as heat sink associated to the SMD-HPLED source... A ceramic material is generally preferred because of its better heat dissipating properties
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A miniature SMD-HPLED replaceable lamp (10) comprising a main body (1) which can be alternatively made of ceramic or metallic material, an electrical connector (20) housed in said main body (1) and a PCB (3a) embedding an HPLED lighting source. The connector (20) is suitably designed both for assuring an electrical continuity between PCB (3a) and an external power supply and locking it in a slot (2) formed on said main body (1).