Elevated LED Lamp Structure for Thermal Management
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Solution Overview
Problem
Conventional LED-based lamps struggle to achieve omnidirectional emission patterns while maintaining efficiency, reliability, and cost-effectiveness, often resulting in complex and expensive designs that fail to meet standard uniformity requirements and suffer from heat dissipation issues.
Innovation Solution
The use of thermally conductive elevating elements, such as heat pipes, to mount LEDs above the lamp base, allowing for efficient heat dissipation and remote placement of LEDs, which enables higher drive currents and improved luminous flux, combined with a diffuser to achieve desired emission patterns that meet stringent energy efficiency and uniformity standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If LEDs are mounted directly on the lamp base, then heat dissipation is improved, but omnidirectional emission pattern cannot be achieved
Solution Approach 1:
The lamp structure is divided into separate functional components: the lamp base for heat dissipation and the elevated LED mounting structure for light emission. This segmentation allows the heat sink to be optimized for thermal management while the LED array is positioned to achieve omnidirectional emission patterns, resolving the contradiction between heat dissipation efficiency and emission uniformity.
Solution Approach 2:
The LED mounting structure is elevated above the lamp base in the vertical dimension, creating spatial separation between the heat source and the emission zone. This dimensional change enables the LEDs to be positioned at an optimal height for omnidirectional light distribution while the lamp base continues to function as an effective heat sink below.
2Shape
If complex designs are used to achieve omnidirectional emission, then emission uniformity is improved, but device complexity and cost increase
Solution Approach 1:
Multiple LED elements are merged into a single elevated mounting structure that functions as an integrated light-emitting component. This consolidation achieves omnidirectional emission through the geometric arrangement of LEDs on the elevated structure without requiring complex individual components or assemblies, thereby simplifying the overall device while maintaining emission uniformity.
Solution Approach 2:
The elevated LED mounting structure serves multiple functions simultaneously: it positions the LEDs for optimal omnidirectional emission, provides a platform for electrical connections, and maintains appropriate thermal spacing. This multi-functionality reduces the need for additional specialized components, lowering device complexity and cost.
3Temperature
If LEDs are placed close to the lamp base, then heat dissipation is improved, but LED lifespan decreases due to higher temperatures
Solution Approach 1:
The LEDs are extracted from direct contact with the lamp base and mounted on an elevated structure. This extraction creates thermal spacing that reduces heat transfer to the LED components, lowering their operating temperature and extending lifespan, while the lamp base continues to dissipate heat effectively through its dedicated heat sink structure.
4Illumination intensity
If drive currents are increased to improve luminous flux, then light output is improved, but heat generation increases
Solution Approach 1:
The elevated mounting structure acts as an intermediary between the LEDs and the lamp base heat sink. This intermediary positioning allows the LEDs to operate at higher drive currents for increased luminous flux while the thermal spacing provided by the elevation reduces direct heat transfer, and the lamp base continues to dissipate the generated heat effectively.
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 solution allows for the production of LED lamps that operate at lower temperatures, increase LED lifespan, and provide omnidirectional emission patterns with intensity variation within ±20% or less, meeting ENERGY STAR requirements and resembling traditional incandescent light bulbs in form and function, while reducing thermal 'cross-talk' and enhancing color mixing.
Implementation Method 1
The lamps described in this patent can comprise a solid state light source that transmits light through a separator to a disperser having a phosphor. The disperser can disperse the light in a desired pattern and/or changes its color by converting at least some of the light through a phosphor.
Implementation Method 2
Heat from the solid state light sources conducts to the heat sink structure through the heat pipe
Implementation Method 3
The LED chip can emit a different wavelength of light such that it emits a combination of light from the LED and the phosphor
Implementation Method 4
The phosphors absorbing at least some of the LED light
Implementation Method 5
The disperser can disperse the light in a desired pattern
Data Source
AI summary
LED based lamps and bulbs are disclosed that comprise an elevating element to arrange LEDs above the lamp or bulb base. The elevating element can at least partially comprise a thermally conductive material. A heat sink structure is included, with the elevating element thermally coupled to the heat sink structure. A diffuser can be arranged in relation to the LEDs so that at least some light from the LEDs passes through the diffuser and is dispersed into the desired emission pattern. In some lamps and bulbs utilize a heat pipe for the elevating elements, with heat from the LEDs conducting through the heat pipe to the heat sink structure where it can dissipate in the ambient.