SSL Lighting Apparatus with Flex-Circuit and Heat Dissipation
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Solution Overview
Problem
Existing solid-state lighting (SSL) apparatuses face challenges in evenly distributing current and efficiently dissipating heat, which can lead to inefficiencies and limitations in thin, economical designs suitable for various applications like signage and general lighting.
Innovation Solution
A flexible circuit with opposing power bus portions and SSL elements connected between them, attached to a frame with multiple surfaces, and a light-diffusive panel with disruptions for even light distribution, allowing for thin and efficient heat dissipation and current control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If SSL elements are placed along edges of a light-transmitting panel for even light distribution, then light uniformity is improved, but heat dissipation becomes insufficient leading to inefficiencies
Solution Approach 1:
The patent transitions from traditional edge-lit configuration to a back-lit configuration where SSL elements are mounted on a circuit board positioned behind the light-transmitting panel. This dimensional repositioning allows heat to dissipate toward the rear of the device while light distributes uniformly through the panel from behind, resolving the conflict between light uniformity and heat dissipation.
Solution Approach 2:
The patent introduces a heat sink as an intermediary component between the SSL elements and the environment. The heat sink absorbs thermal energy from the SSL elements and dissipates it efficiently, decoupling the heat management function from the light distribution function and allowing both to optimize their respective performances.
2Temperature
If traditional lighting structures are used, then heat dissipation is adequate, but the apparatus becomes too thick and not economical
Solution Approach 1:
The patent employs a thin flexible circuit board to mount the SSL elements, replacing bulky traditional lighting structures. The circuit board serves as both a mechanical support and an electrical connection medium, enabling thin-profile construction while maintaining adequate heat dissipation through its extended surface area and integration with heat sink structures.
Solution Approach 2:
The patent combines multiple functions into integrated components: the circuit board serves as both structural support and electrical pathway, the heat sink integrates with the mounting structure to provide both mechanical attachment and thermal management, eliminating the need for separate thick components and achieving a thin overall profile.
3Illumination intensity
If SSL elements are densely packed for better light output, then illumination intensity is improved, but current distribution becomes uneven
Solution Approach 1:
The patent designs the circuit board with carefully controlled trace geometries and impedance matching to ensure uniform current distribution across all SSL elements. By maintaining equipotential conditions and minimizing resistance variations in the power delivery network, the system achieves consistent current flow to densely packed elements, preventing hotspots and ensuring uniform light output.
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 enables even current distribution and efficient heat dissipation, resulting in a thin, economical SSL apparatus suitable for diverse applications by using a flexible circuit and light-diffusive panel configuration.
Implementation Method 1
light from the SSL elements is spread evenly through the panel by total internal reflection
Implementation Method 2
Disruptions formed on the surface of the panel scatter incident light so that light is emitted from the surface of the panel
Data Source
AI summary
A disclosed lighting apparatus includes a flex-circuit, a frame, and a light-diffusive panel. The flex-circuit includes a power bus having first and second portion of opposite polarity disposed parallel to outer edges of the flex-circuit, and solid-state lighting (SSL) elements disposed and connected between the portions of the power bus. A first side of the frame includes a first surface to which a portion of the flex-circuit having the first portion of the power bus is attached, a second surface to which a portion of the flex-circuit having the SSL elements is attached, and a third surface to which a portion of the flex-circuit having the second portion of the power bus is attached. A face of the light-diffusive panel abuts the first surface of the frame, and side of the light-diffusive panel faces the second surface of the frame and light emitting portions of the SSL elements.