LED Light Bulb Heat Dissipation via Segmented Driver and Metal Substrate
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Solution Overview
Problem
LED components in light bulbs require effective temperature management to prolong lifespan, and existing designs often compromise on cost and manufacturing efficiency while achieving this.
Innovation Solution
A light bulb apparatus featuring a substrate plate made of a heat dissipation material, an inner tube also made of heat dissipation material, and an outer cup of isolation material, with a driver that alternates the activation of LED modules to manage heat distribution and prevent overheating, enhancing heat dissipation and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If LED modules are continuously operated to maintain lighting function, then illumination is provided, but heat accumulates and LED lifespan decreases
Solution Approach 1:
The driver alternately activates different LED modules in groups, allowing some modules to rest and cool down while others operate. This periodic operation pattern prevents continuous heat accumulation in all LED modules, extending their lifespan while maintaining continuous lighting output.
Solution Approach 2:
The LED modules are divided into multiple groups that can be independently controlled. By segmenting the LED array and activating different groups at different times, the system distributes heat generation across space and time, preventing localized overheating while maintaining overall illumination.
2Duration of action of stationary object
If heat dissipation structures are added to manage LED temperature, then LED lifespan is extended, but manufacturing cost increases
Solution Approach 1:
The substrate plate serves dual functions: it provides mechanical support for mounting LED modules and simultaneously acts as a heat dissipation component through its metal construction with integrated heat dissipation fins. This merging of structural and thermal management functions eliminates the need for separate heat sinks, reducing part count and manufacturing cost.
Solution Approach 2:
The inner tube structure is designed to perform multiple functions: it provides mechanical support, facilitates heat dissipation through its metal construction, and enables airflow channels for convective cooling. This multi-functionality reduces the need for additional specialized components, lowering overall manufacturing cost.
3Temperature
If metal materials are used for heat dissipation components, then heat dissipation efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The substrate plate is constructed from thin metal material with integrated heat dissipation fins that are formed through stamping or extrusion processes. This thin-film approach provides effective heat dissipation while simplifying manufacturing compared to thick, complex metal structures, reducing both material cost and processing complexity.
Solution Approach 2:
Traditional mechanical assembly methods for attaching heat dissipation components are replaced by integrating heat dissipation fins directly into the substrate plate through forming processes. This substitution eliminates multiple assembly steps, reduces manufacturing complexity, and improves heat transfer efficiency through direct contact.
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 design extends the lifespan of LED modules, ensures efficient heat dissipation, and reduces manufacturing costs by using cost-effective materials and innovative heat management strategies.
Implementation Method 1
The substrate plate is made of a first heat dissipation material... The inner tube part is made of a second heat dissipation material
Implementation Method 2
the spacing portion forms one or more hole for keeping air flowing inside the light bulb apparatus for enhancing heat dissipation
Implementation Method 3
The outer cup part is made of an isolation material... the isolation material is a plastic material with less heat dissipation ratio than the inner tube for protecting users
Data Source
AI summary
A light bulb apparatus has a bulb shell, LED modules, a light source plate, an inner tube and an outer cup. The light source plate has a substrate plate. The substrate plate and the inner tube are made of heat dissipation material like metal material. There is a pressing portion of a lateral side of the substrate plate pressing against an inner side of the inner tube part and there is a spacing portion of the lateral side of the substrate plate not engaging the inner side of the inner tube. The outer cup part has top part and a bottom part. The inner cup is placed inside the top part of the outer cup and pressing against the outer cup.