Socket Convex Sections for Thermal Conductivity and Mechanical Strength
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Solution Overview
Problem
Lighting devices face challenges in balancing thermal conductivity for heat dissipation with mechanical strength and resistance to external forces, as increasing filler content in thermally conductive resins enhances thermal conductivity but reduces brittleness and mechanical strength.
Innovation Solution
The design incorporates a socket with a flange section, first and second convex sections, and a third convex section, where the second and third convex sections are positioned to enhance air flow and heat dissipation while improving mechanical strength by connecting fins and flange sections, and the third convex section is placed inside a concave section to prevent heat accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the content of filler is increased in thermally conductive resin, then thermal conductivity is improved, but brittleness is increased and mechanical strength is lowered
Solution Approach 1:
The patent employs a composite material structure consisting of a resin base material reinforced with carbon fibers or carbon nanotubes. This composite approach allows the socket to achieve high thermal conductivity through the carbon-based filler while the resin matrix maintains mechanical strength and reduces brittleness, effectively resolving the contradiction between thermal performance and mechanical properties
Solution Approach 2:
The patent optimizes the filler content within a specific range (10-40 wt%) rather than using maximum filler loading. This parameter optimization ensures sufficient thermal conductivity while preventing excessive brittleness and maintaining mechanical strength, achieving a balance between thermal and mechanical requirements
2Temperature
If the content of filler is increased in thermally conductive resin, then thermal conductivity is improved, but resistance to external force is lowered
Solution Approach 1:
The composite structure of resin combined with carbon fibers or carbon nanotubes provides both thermal conduction pathways and mechanical reinforcement. The carbon fibers/nanotubes enhance thermal conductivity while the resin matrix maintains structural integrity and resistance to external forces, preventing the socket from becoming too brittle
Solution Approach 2:
The patent introduces convex sections with specific geometric features (inclined surfaces, curved surfaces) at critical locations of the socket. These localized structural modifications enhance resistance to external forces and improve heat dissipation efficiency at key areas without requiring uniform increases in filler content throughout the entire socket, thereby maintaining mechanical reliability
3Temperature
If metal is used as socket material for high thermal conductivity, then heat dissipation is improved, but weight is increased
Solution Approach 1:
The patent replaces traditional metal materials with a thermally conductive resin composite containing carbon fibers or carbon nanotubes. This substitution achieves comparable thermal conductivity to metal while significantly reducing the weight of the socket, as carbon-based composites have much lower density than metals like aluminum or copper
Solution Approach 2:
The patent optimizes the filler content (10-40 wt%) and selects specific carbon-based materials (carbon fibers, carbon nanotubes) to achieve the desired thermal conductivity level. This parameter optimization allows the resin composite to reach thermal performance close to metal while maintaining the weight advantage of polymer materials
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
This configuration effectively improves both heat dissipation and mechanical resistance to external forces, ensuring efficient heat release and structural integrity while minimizing weight and manufacturing costs.
Implementation Method 1
Heat generated in the light emitting diode is mainly discharged to the outside through the socket. Thus, the socket is formed of a material having a high thermal conductivity.
Implementation Method 2
a first surface intersecting the first convex section and a second surface facing the first surface. At least one of the first surface and the second surface is inclined such that a distance between the first surface and the second surface is gradually shortened toward the top surface of the second convex section. since air flow is smooth, it is possible to improve the heat dissipation.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6C
AI summary
According to one embodiment, a socket (1,110) includes a flange section (12,112) in which a light emitting module (20) having a light emitting element (22) is provided; a first convex section (13) that protrudes from a surface of the flange section (12,112) opposite to a side on which the light emitting module is provided and has a plate shape; and a second convex section (14) that protrudes from the surface of the flange section opposite to the side on which the light emitting module is provided and is connected to the first convex section. A top surface (14a) of the second convex section is positioned further on the flange section side with respect to a top surface (13a) of the first convex section.