LED Bulb Shell with Integrated Cooling Channels
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Solution Overview
Problem
Existing LED lighting solutions face challenges due to their point source nature and need for low-temperature operation, leading to complexity, cost, efficiency loss, and undesirable form factors, while maintaining optical and electrical efficiency.
Innovation Solution
The development of advanced LED light bulbs with bulb shells featuring surface texture and optical transflective films, combined with small-size heat sinks and various LED configurations, including cooling air channels to manage heat dissipation and optimize light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional cooling solutions (fans, thermal sinks, heat pipes) are used to manage LED heat dissipation, then the LED can operate at required temperatures, but the device complexity, cost, and failure modes increase
Solution Approach 1:
The patent combines the shell structure with cooling air channels integrated directly into it, merging the protective enclosure function with the thermal management function. This eliminates the need for separate cooling components like fans or external heat pipes, reducing device complexity while maintaining effective heat dissipation from the LED
Solution Approach 2:
The shell serves multiple functions simultaneously: it provides structural support, protects internal components, and acts as a heat dissipation pathway through integrated air channels. This multi-functionality reduces the number of separate components needed, lowering complexity and potential failure modes while maintaining proper LED operating temperatures
2Illumination intensity
If LEDs are configured as point sources, then the light output is concentrated, but the light distribution becomes undesirable and requires additional optical components
Solution Approach 1:
The patent transitions from point source LEDs to an extended linear light source configuration by positioning LEDs along the shell perimeter. This dimensional change allows light to be emitted from multiple locations simultaneously, creating more uniform area illumination without requiring additional optical redistribution components
3Ease of manufacture
If the LED shell is made smooth and simple, then manufacturing is easier, but light distribution control becomes ineffective
Solution Approach 1:
The patent applies surface texture only to the portions of the shell that interact with light (inner or outer surfaces), while maintaining simple smooth geometry for the overall shell structure and non-lighting areas. This localized application of complexity maintains ease of manufacturing for the bulk structure while achieving effective light distribution control where needed
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 approach enhances the performance and light distribution of LED bulbs by efficiently managing heat and light, offering attractive manufacturing costs and design benefits while maintaining energy efficiency.
Implementation Method 1
at least a portion of the light exits from the shell and is redirected by the texture
Implementation Method 2
cooling air channels to manage heat dissipation
Data Source
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AI summary
A solid state light having a shell forming an interior volume and with surface texture for redirecting light. A light section is coupled to the shell, and a light source board in the light section includes at least one solid state light source such as an LED. The shell, light section, and light source board have apertures for providing an air cooling channel through the light. The solid state light source transmits light into the interior volume, and the light exits from the shell and is redirected by the surface texture, providing for various light distribution curves of the light.