Gas Cooled LED Lamp Central Submount Design
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Solution Overview
Problem
LED lighting systems face challenges in achieving a light pattern similar to traditional incandescent or fluorescent bulbs due to the presence of power supplies and heatsinks, which can hinder light emission and limit LED placement.
Innovation Solution
The use of a light transmissive submount and a gas-based thermal coupling system allows the LEDs to be centrally located within the lamp, minimizing the impact of heatsinks and mounting hardware on the light pattern, while using a thermally resistive electrical path for sealing and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heatsink and power supply are included in the lamp structure, then the LEDs can be cooled and powered efficiently, but the light pattern is hindered and LED placement is limited
Solution Approach 1:
The patent extracts the heatsink and power supply from the traditional bulb structure, removing these components that were blocking light and limiting LED placement. The LEDs are now cooled through the bulb base rather than through a traditional heatsink, allowing unobstructed light emission from the bulb envelope.
Solution Approach 2:
The patent changes the cooling approach from a lateral heatsink structure to a base-mounted cooling system. The thermal path is redirected through the bulb base, allowing the LEDs to be positioned centrally in the bulb without requiring side-mounted heatsinks that would block light.
2Illumination intensity
If the LEDs are mounted close to the base of the lamp, then the light pattern is less affected by mounting hardware, but the LEDs are harder to cool efficiently
Solution Approach 1:
The patent introduces the bulb base as an intermediary thermal pathway. The base serves as both the mounting structure and the cooling conduit, conducting heat away from the centrally positioned LEDs through its thermal mass and connection to the external environment.
3Temperature
If a traditional heatsink is used, then the LEDs can be cooled, but the light emission is blocked and LED placement is limited
Solution Approach 1:
The patent removes the traditional heatsink component entirely, extracting its cooling function and redistributing it through the bulb base structure. This simplifies the overall lamp design by eliminating the heatsink while maintaining effective LED cooling.
Solution Approach 2:
The bulb base is given multiple functions: it serves as the mounting structure for the LEDs, the electrical connection point, and the primary cooling conduit. This multi-functionality eliminates the need for separate heatsink and mounting hardware components.
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 configuration enables efficient operation and long life of LEDs with an unobstructed light pattern, allowing the LED lamp to mimic the light distribution of traditional bulbs without the limitations imposed by power supplies and heatsinks.
Implementation Method 1
a gas in the enclosure provides thermal coupling to the LED array
Data Source
AI summary
A gas cooled LED lamp and submount is disclosed. The centralized nature of the LEDs allows the LEDs to be configured near the central portion of the optical envelope of the lamp. In some embodiments, the LEDs can be mounted on or fixed to a light transmissive submount. In some embodiments, LEDs can be disposed on both sides of a two-sided submount, or on thee or more sides if the submount structure includes three or more mounting surfaces. In example embodiments, the LEDs can be cooled and/or cushioned by a gas in thermal communication with the LED array to enable the LEDs to maintain an appropriate operating temperature for efficient operation and long life. In some embodiments, the gas is at a pressure of from about 0.5 to about 10 atmospheres and has a thermal conductivity of at least about 60 mW/m-K.