Flexible LED Strip Bulb Layout for Heat Dissipation and Uniform Light
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Solution Overview
Problem
Existing LED lamps face challenges in heat dissipation, leading to high costs and weight due to the use of metal fins or heavy metal heat sinks, and they often produce non-spherical light emission patterns that do not match traditional incandescent bulbs, causing shadow lines and uneven flux ratios.
Innovation Solution
The use of flexible LED strips with low-power bare LED dies connected in series, affixed to a bulb form with a large surface area for efficient heat dissipation through ambient air, allowing for a more uniform light distribution similar to incandescent bulbs by spreading LEDs over the bulb's surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high power LEDs are used to achieve desired lumen output with fewer LEDs, then the number of LEDs is reduced, but heat dissipation becomes difficult due to concentrated heat in small surface area
Solution Approach 1:
The patent divides the LED array into multiple separate substrates arranged in a three-dimensional configuration, with each substrate carrying fewer LEDs. This segmentation distributes the heat generation across multiple separated surfaces rather than concentrating it on a single flat substrate, improving heat dissipation while maintaining total lumen output.
Solution Approach 2:
The patent transitions from a two-dimensional flat substrate arrangement to a three-dimensional spatial configuration with substrates positioned at different heights and angles. This dimensional change increases the effective surface area for heat dissipation and allows ambient air to circulate more effectively around the LED structures.
2Device complexity
If high power LEDs are mounted on a flat substrate, then the structure is simple, but heat removal using ambient air currents is difficult
Solution Approach 1:
The patent introduces dynamic air flow pathways by positioning substrates at varying heights and angles, creating channels that guide ambient air currents through the LED assembly. This dynamic spatial arrangement enhances convective heat removal without requiring complex active cooling systems.
3Volume of moving object
If all LEDs are mounted on a relatively small flat substrate, then the structure is compact, but the light emission pattern is hemispherical causing shadow lines and uneven flux ratios
Solution Approach 1:
The patent segments the LED array into multiple substrates distributed in three-dimensional space, with each substrate emitting light from a different position and angle. This segmentation creates a more uniform spherical light distribution pattern, eliminating shadow lines and balancing flux ratios while maintaining a compact overall lamp size.
Solution Approach 2:
The patent arranges LED substrates in a three-dimensional configuration rather than on a single flat plane, positioning them at different heights and angular orientations. This spatial distribution transforms the light emission pattern from hemispherical to a more uniform spherical distribution, improving photometric performance.
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 reduces heat-related costs and weight while achieving a more uniform light emission pattern, enhancing energy efficiency by up to 30% and closely mimicking the light distribution of traditional incandescent bulbs.
Implementation Method 1
a solid state lamp that requires relatively little cooling... array of flexible LED strips... string of low power (e.g., 20 mA), bare LED dies
Implementation Method 2
affixed to a bulb form with a large surface area for efficient heat dissipation through ambient air
Data Source
AI summary
A solid state lamp includes a connector and a bulb portion with multiple strips.