Miniature Integrated LED Bulb with Nested Heatsink and Light Pipe
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Solution Overview
Problem
Existing LED replacement lamps face challenges in meeting standards for lumen maintenance, heat management, and form factor constraints, particularly when retrofitting or replacing standard incandescent or halogen lamps.
Innovation Solution
The development of a miniature integrated LED lamp with a unique design that includes a semi-cylindrical light pipe, a transparent light diffuser, a cylindrical heatsink, and a multilayer flexible printed circuit board, which enables efficient thermal management and unobstructed light emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple LED dies or chips are mounted within an LED package to achieve high luminous output, then the light output is improved, but the heat management becomes more difficult and the form factor constraints are harder to meet
Solution Approach 1:
The patent implements a nested structure where the light pipe is positioned inside the transparent envelope, the heatsink is positioned inside the light pipe, and the LED array is mounted on the heatsink. This nested arrangement allows multiple functional components to occupy minimal space while maintaining their individual functions, enabling effective heat management from multiple LEDs within a compact form factor that meets standard lamp replacements.
Solution Approach 2:
The patent introduces a light pipe as an intermediary component between the LED array and the transparent envelope. The light pipe receives light from the LEDs and distributes it omnidirectionally, while also serving as a structural element that holds the heatsink. This intermediary structure enables the system to manage heat from multiple LEDs effectively while maintaining high luminous output and meeting form factor constraints.
2Adaptability or versatility
If a compact form factor is used to replace standard incandescent bulbs, then the adaptability is improved, but the space for heat management components is reduced
Solution Approach 1:
The patent employs a nested configuration where the heatsink is positioned inside the light pipe, which in turn is positioned inside the transparent envelope. This nested arrangement maximizes the use of available internal space within a compact form factor, allowing adequate heat management components to be accommodated without increasing the external dimensions, thus maintaining compatibility with standard lamp sockets and fixtures.
Solution Approach 2:
The patent utilizes the vertical dimension by positioning the heatsink along the central axis within the light pipe, rather than spreading heat management components horizontally. This vertical arrangement allows efficient heat management within the constrained radial space of a compact bulb form factor, enabling standard replacement dimensions while maintaining adequate thermal management capability.
3Illumination intensity
If a transparent envelope is used to allow light emission, then the light transmission is improved, but the heat management efficiency is reduced
Solution Approach 1:
The patent introduces the light pipe as an intermediary structure between the heat-generating LED array and the transparent envelope. The light pipe serves dual functions: it distributes light omnidirectionally to maximize light transmission through the envelope, and it provides a structural framework to position the heatsink for effective heat management. This intermediary structure resolves the conflict between transparent envelope light transmission and heat management efficiency.
Solution Approach 2:
The patent segments the bulb into distinct functional zones: the inner region contains the LED array mounted on the heatsink for heat management, the middle region contains the light pipe for light distribution, and the outer region is the transparent envelope for light transmission. This segmentation allows each component to optimize its function without interfering with others, enabling both effective heat management and high light transmission through the transparent envelope.
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 achieves high luminous output, efficacy, and color rendering index, while meeting stringent performance standards and extending the lumen maintenance life, thus addressing the challenges of heat management and form factor constraints.
Implementation Method 1
When a diode is forward biased (switched on), electrons can recombine with holes within the device, releasing energy in the form of photons. This effect is called electroluminescence
Implementation Method 2
cylindrical heatsink... enabling efficient thermal management
Implementation Method 3
transparent light diffuser... enabling unobstructed light emission
Implementation Method 4
transparent light diffuser... enabling unobstructed light emission
Data Source
AI summary
The present disclosure relates to various embodiments to enable the assembly, construction, and operation of a miniature integrated LED lamp comprising an envelope positioned at a distal end of a solid body portion and a base positioned at a proximal end of the solid body. The envelope further comprises a transparent light diffuser enclosing a semi-cylindrical light pipe containing one or more LEDs populated on its external surface and a LED driver positioned internally within a formed lumen of the light pipe. The light pipe and LED driver are physically and or electrically connected to a cylindrical heatsink encapsulated within the envelope and body portion of the bulb, facilitating thermal management. The envelope and base are assembled together with one or more specific lamp bases to form an LED lamp satisfying performance standards suitable for retrofit or replacement of a standard INC or halogen lamp.