LED Light Bulb Thermal Management via Integrated Substrate
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Solution Overview
Problem
Conventional LED light bulbs face limitations such as high fabrication costs due to manual assembly, limited directional light output, and heat dissipation issues, which affect their performance and longevity.
Innovation Solution
The development of an LED light bulb with a substrate-based light engine that includes patterned electrical traces and a heat conduit, forming a rigid upright support structure for the LED, along with a thermally conductive and transmissive cover to enhance heat dissipation and light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional LED light bulb uses a separate heatsink arranged between the base and globe, then heat dissipation is improved, but light output in directions proximate to the base is blocked and directional light output is limited
Solution Approach 1:
The patent merges the heatsink function with the bulb housing structure itself. The housing is made of thermally conductive material that serves both as structural support and heat dissipation pathway, eliminating the need for a separate heatsink component that would block light. This integration allows heat to be conducted away from the LED while maintaining clear light paths in all directions.
Solution Approach 2:
The bulb housing is designed to perform multiple functions simultaneously: providing structural support, enabling heat dissipation through its thermally conductive material, and allowing unobstructed light output in all directions. This multi-functional design replaces the conventional separate heatsink component without compromising thermal management.
2Manufacturing precision
If manual assembly is used to make mechanical, electrical, and thermal connections in conventional LED light bulbs, then assembly precision is improved, but fabrication cost increases
Solution Approach 1:
The patent combines mechanical support, electrical connection, and thermal conduction functions into a single integrated housing structure. This eliminates the need for separate components requiring manual assembly for each function, allowing automated manufacturing processes to be used instead, thereby reducing fabrication costs while maintaining assembly precision.
Solution Approach 2:
The housing structure is designed as a multi-functional component that provides mechanical support, electrical connectivity, and thermal management simultaneously. This integration reduces the number of assembly steps required and enables more efficient automated manufacturing, lowering overall fabrication costs.
3Temperature
If a thermally conductive cover is used to enhance heat dissipation, then temperature control is improved, but light transmission may be reduced
Solution Approach 1:
The patent applies local quality by using thermally conductive material strategically in areas where heat dissipation is critical (near the LED and housing base) while maintaining optical transparency in areas where light transmission is paramount (the cover portions through which light exits). This localized material property assignment optimizes both thermal management and light transmission.
Solution Approach 2:
The housing employs composite material construction combining thermally conductive materials for structural components with optically transparent thermally conductive materials for cover portions. This allows the system to achieve effective heat dissipation through the housing structure while maintaining high light transmission through the transparent cover sections.
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 design reduces fabrication costs, improves heat dissipation, and enhances light output in a wider range of directions, prolonging LED lifespan and improving overall performance.
Implementation Method 1
the substrate includes at least one heat conduit portion with which the at least one LED is arranged in conductive thermal communication
Implementation Method 2
at least a portion of the cover comprises a material having visible spectrum transmittance of at least about 80% and a thermal conductivity of at least 25 W/(m·° K)
Data Source
AI summary
LED light bulbs include openings in base or cover portions, and optional forced flow elements, for convective cooling. Thermally conductive optically transmissive material may be used for cooling, optionally including fins. A LED light engine may be fabricated from a substrate via planar fabrication techniques and shaped to form a substantially rigid upright support structure. Mechanical, electrical, and thermal connections may be made between a LED light engine and a LED light bulb.