LED Bulb Filament Adhesion and Helium Cooling

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Solution Overview

Problem

Conventional LED lighting devices pose risks of electric shock, have complex and costly manufacturing due to grooves for filaments, interfere with heat dissipation, reduce luminous efficiency with transparent insulation layers, and make filaments difficult to bend and fix securely.

Innovation Solution

A hollow, sealed, translucent envelope with a filament partially attached to its inner surface via an adhering layer, electric wires connected securely without direct contact, and a flexible light-emitting strip with enhanced heat dissipation using helium gas, allowing for various envelope shapes and improved filament attachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a groove is formed in the translucent envelope to receive the LED filament, then electric shock risk is avoided, but the shape options of the envelope are restricted and manufacturing cost increases

Engineering Contradiction:

Improveelectric shock safetyVSAvoidenvelope manufacturing cost and complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

A transparent insulation layer is introduced as an intermediary component between the LED filament and the translucent envelope. This layer provides the necessary electrical insulation to prevent electric shock while maintaining the simplicity of the envelope structure and allowing diverse shape options. The insulation layer acts as a mediator that solves the safety issue without requiring modifications to the envelope itself.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a transparent insulation layer is added to cover the LED filament for safety, then electric shock risk is avoided, but heat dissipation is interfered with and service life is reduced

Engineering Contradiction:

Improveelectric shock safetyVSAvoidheat dissipation capability

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent employs a thin transparent insulation layer that provides electrical safety while minimizing thermal resistance. The thin film structure allows heat to pass through effectively, maintaining good heat dissipation performance. Additionally, the insulation layer is designed with high thermal conductivity materials to further enhance heat transfer from the LED filament to the surrounding environment.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If a transparent insulation layer is used to cover the LED filament, then electric shock risk is avoided, but luminous efficiency is reduced due to light absorption

Engineering Contradiction:

Improveelectric shock safetyVSAvoidluminous efficiency

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The transparent insulation layer is designed with specific optical properties, including high transparency in the visible spectrum and appropriate refractive index matching. This minimizes light absorption and scattering, thereby reducing the impact on luminous efficiency. The layer's optical characteristics are optimized to allow maximum light transmission while maintaining electrical insulation functionality.

Inventive Principle:

Principle #32Color changes

4Reliability

If the LED filament is covered by a transparent insulation layer, then electric shock risk is avoided, but the filament becomes hard and difficult to bend and fix

Engineering Contradiction:

Improveelectric shock safetyVSAvoidfilament flexibility and installation

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The insulation structure is designed as a segmented or modular system where the transparent insulation layer is applied in sections or as a loose-fitting cover rather than a rigid encapsulation. This segmentation maintains the flexibility of the LED filament, allowing it to be bent and installed in various configurations while still providing comprehensive electrical insulation protection.

Inventive Principle:

Principle #1Segmentation

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

Eliminates electric shock risk, reduces manufacturing costs, enhances heat dissipation, increases luminous efficiency, and allows for flexible filament attachment and longer service life.

Implementation Method 1

an adhering layer disposed at the light-emitting strip and partially attached to the inner surface of the envelope

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

enhances heat dissipation using helium gas

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP4180709A1LED bulb

Publication Date: 2023.05.17 LIQUIDLEDS LIGHTING

Figure 1~2
Figure 3~4
Figure 5~6

AI summary

An LED bulb has an envelope (10), an electrical connector (12), a filament (20), and at least one electric wire (30). The envelope (10) is hollow, sealed, and translucent and has a containing portion (11) being enclosed, a neck portion (13) disposed at the containing portion (11), and an envelope axis (103) passing through the containing portion (11) and the neck portion (13). The electrical connector (12) is connected to the neck portion (13). The filament (20) is inside the containing portion (11), is partially attached to an inner surface of the envelope (10), and has a light-emitting strip (41) having multiple LEDs (411) and an adhering layer (42) disposed at the light-emitting strip (41) and partially attached to the inner surface of the envelope (10). The at least one electric wire (30) is electrically connected to the filament (20) and the electrical connector (12).