Glass Frit Coating for LED Diffuser Heat Resistance
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Solution Overview
Problem
Conventional LED lamp diffusers made of synthetic resin are prone to deformation and discoloration due to heat and light, leading to poor durability and short service life, and require separate manufacturing and assembly with metal heat sinks, increasing costs and reducing productivity.
Innovation Solution
A color coating composition using glass frits, ceramic fillers, and inorganic pigments is applied to transparent or translucent glass sheets to create a durable and heat-resistant diffuser that maintains lighting quality and appearance over time, with a composition of 50 wt% binder solution, 40-44 wt% glass frits, 5-8 wt% ceramic filler, and 1-3 wt% inorganic pigment, and a manufacturing process involving fusing, wet-pulverization, and ball milling to achieve 2-4 μm particle sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a synthetic resin diffuser is used in conventional LED lamps, then the diffuser can be easily manufactured and assembled, but it deforms and discolors due to heat and light, resulting in poor durability and short service life
Solution Approach 1:
The patent changes the material parameters by replacing synthetic resin with inorganic glass frit-based coating. This material substitution fundamentally alters the thermal and optical stability parameters, enabling the diffuser to withstand high temperatures and UV light without deformation or discoloration, thereby resolving the durability issue while maintaining manufacturability through coating processes
Solution Approach 2:
The patent employs a composite coating system consisting of inorganic glass frits as the base material, combined with ceramic fillers and inorganic pigments. This composite structure provides both the heat resistance and light stability required for durability, while the glass frit matrix ensures adhesion and structural integrity, solving the contradiction between ease of manufacture and reliability
2Ease of manufacture
If a synthetic resin diffuser is used in conventional LED lamps, then the diffuser can be easily manufactured, but it requires separate manufacturing and assembly with metal heat sinks, increasing costs and reducing productivity
Solution Approach 1:
The patent merges the diffuser function directly onto the glass lamp envelope through coating application. This eliminates the need for separate diffuser components and their assembly with heat sinks, integrating multiple functions into a single structure. The coating process applies the diffuser layer directly to the lamp glass, reducing assembly steps and improving productivity while maintaining ease of manufacture
Solution Approach 2:
The inorganic glass frit-based coating serves multiple functions simultaneously: it acts as the diffuser for light distribution, provides heat resistance for thermal management, and offers durability against environmental factors. This multi-functionality eliminates the need for separate components, reducing assembly complexity and improving productivity while keeping the manufacturing process simple
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 solution enhances the durability and lifespan of LED lamps by preventing deformation and discoloration, maintaining lighting quality and appearance, and reducing manufacturing costs through a single, high-strength, translucent glass diffuser that effectively dissipates heat.
Implementation Method 1
a manufacturing process involving fusing, wet-pulverization, and ball milling
Implementation Method 2
a manufacturing process involving fusing, wet-pulverization, and ball milling to achieve 2-4 μm particle sizes
Implementation Method 3
a manufacturing process involving fusing, wet-pulverization, and ball milling to achieve 2-4 μm particle sizes
Data Source
AI summary
Disclosed herein are a color coating composition for an LED lamp diffuser using glass frits and a color-coated glass article using the same. The color coating composition is capable of increasing durability and a life of an LED lamp, satisfactorily maintaining an external appearance and a lighting quality thereof for a long time, and realizing various colors, by manufacturing a glass-made diffuser as a means for diffusing light of the LED lamp in a manner of coating the diffuser on various sheets of transparent or translucent glass such as tubes and bulbs so that the diffuser is not deformed and discolored due to light and heat, and has high strength and translucency.