Staggered Fin Thermal Module for LED Lamp Heat Dissipation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional LED lamp assemblies face challenges in manufacturing low-cost lamp assemblies with high cooling efficiency due to the difficulties in forming complex fin structures using die extrusion and die casting processes, which are expensive and limited in producing fine pitch and durable fin structures.
Innovation Solution
A lamp assembly design featuring a thermal module with a first and second thermal member, where the fins are arranged in a staggered manner to increase the surface area, and a connecting member with thermal fins to enhance heat dissipation, utilizing die casting and metal extrusion processes respectively, and through holes for air convection to prevent overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If die extrusion process is used to form metal fins, then manufacturing cost increases, but fin structure complexity and durability are improved
Solution Approach 1:
The heat dissipation structure is divided into multiple independent fin components that can be manufactured separately using cost-effective die casting processes, then assembled together. This segmentation allows each fin to be produced with simpler, cheaper processes while maintaining the overall structural complexity and durability through precise assembly of the segmented parts.
2Ease of manufacture
If die casting process is used to form metal fins, then manufacturing cost decreases, but fin structure complexity and durability are reduced
Solution Approach 1:
Multiple fins that would individually require complex die extrusion processes are merged into an integrated die-cast component assembly. The merging of multiple simpler die-cast parts achieves the same functional complexity and durability as fewer extruded parts, while significantly reducing manufacturing cost through the use of the more economical die casting process.
3Temperature
If fin pitch is reduced to increase cooling efficiency, then heat dissipation performance improves, but manufacturing difficulty increases
Solution Approach 1:
Instead of reducing fin pitch in a single dimension, the design introduces staggered arrangements and multi-level positioning of fins in additional spatial dimensions. This dimensional approach increases the effective heat dissipation surface area and improves cooling efficiency without requiring excessively tight pitch in any single dimension, thereby avoiding the manufacturing difficulties associated with ultra-fine pitch features.
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 staggered fin arrangement and thermal module design improve cooling efficiency, extending the lifetime and preventing overheating of the LED light source, while maintaining cost-effectiveness.
Implementation Method 1
a lamp assembly design featuring a thermal module with a first and second thermal member, where the fins are arranged in a staggered manner to increase the surface area
Implementation Method 2
through holes for air convection to prevent overheating
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A lamp assembly is provided, including a light source (50), a thermal module (30), a connecting member (20), and an adapter (10) electrically connected to the light source. The thermal module includes a first thermal member (31) and a second thermal member (32). The first and second thermal members respectively have a plurality of first (311) and second fins (321) which are arranged in a staggered manner. The second thermal member forms a plurality of through holes (H) for heat dissipation. The light source is disposed on the second thermal member, and the connecting member connects the thermal module with the adapter.