Flexible Circuit Carrier in LED Base for Heat Dissipation
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Solution Overview
Problem
LED lightbulbs face inefficiency and reduced light output at temperatures above 25°C due to inadequate heat dissipation, and existing designs often alter the size and shape of the bulb to accommodate circuitry, deviating from standard forms.
Innovation Solution
The design incorporates a thermally conductive heatsink, heat pipes, and a heat spreader plate with a thermally conductive and insulating sheet to efficiently dissipate heat from LEDs, maintaining the bulb's standard size and shape by integrating circuitry within the base using a flexible circuit carrier and potting material for thermal and electrical isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heat sink is provided to spread heat, then heat distribution is improved, but heat removal effectiveness deteriorates
Solution Approach 1:
The patent extracts the circuit board and power supply components from the traditional bulb body and relocates them to the base area. This separation allows the main bulb body to be dedicated to heat dissipation functions through the LED array and heat sink, while the base handles electrical functions, thereby improving overall heat removal effectiveness without compromising heat distribution.
Solution Approach 2:
The patent utilizes the vertical space within the base area to accommodate circuitry that would otherwise occupy horizontal space in the bulb body. By moving components to the base dimension, the patent maintains the bulb's standard shape and size while improving heat dissipation performance in the main illumination area.
2Shape
If circuitry is placed in the Edison base, then standard bulb size and shape are maintained, but thermal and electrical isolation becomes more difficult
Solution Approach 1:
The patent nests the flexible circuit carrier within the potting material, which itself is contained within the base structure. This nested arrangement allows the circuit board to be embedded in the base area with proper thermal and electrical isolation provided by the potting material, maintaining the standard bulb shape while protecting against harmful thermal and electrical effects.
Solution Approach 2:
The patent introduces potting material as an intermediary substance between the flexible circuit carrier and the base structure. This potting material provides both thermal and electrical isolation, preventing harmful heat and electricity transfer while allowing the circuitry to be securely mounted in the base area, thus maintaining standard bulb dimensions.
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 effectively maintains the light output and extends the operational lifetime of LEDs by efficiently dissipating heat, ensuring the bulb operates efficiently and maintains a standard form factor.
Implementation Method 1
a thermally conductive heatsink
Implementation Method 2
efficiently dissipate heat from LEDs
Implementation Method 3
heat pipes
Implementation Method 4
heat pipes
Implementation Method 5
a heat spreader plate with a thermally conductive and insulating sheet
Implementation Method 6
potting material for thermal and electrical isolation
Implementation Method 7
potting material for thermal and electrical isolation
Data Source
AI summary
A device has an electrical connector, a radiation generator, and a flexible carrier with circuitry that is operatively coupled between the connector and the radiation generator. In response to electrical power received through the connector, the circuitry energizes the radiation generator, and the radiation generator emits radiation. In a different embodiment, a device has an electrical connector, a radiation generator, and a member with circuitry embedded therein. The circuitry is operatively coupled between the connector and the radiation generator. In response to electrical power received through the connector, the circuitry energizes the radiation generator, and the radiation generator emits radiation.