LED Corn Lamp Baseplate Segmentation for Uniform Heat Conduction
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Solution Overview
Problem
Existing LED energy-saving lamps face issues with non-uniform heat conduction and increased complexity and cost due to the use of straight aluminum baseplates in U-shaped or H-shaped tubes, leading to inconsistent illumination and potential damage to glass tubes during assembly.
Innovation Solution
The design features a baseplate with two parallel branches and a connecting part, allowing for uniform heat conduction and simplified assembly by ensuring all LED lamp beads emit light in the same direction, with a semi-liquid adhesive filling D-shaped cavities for improved thermal conductivity and reduced stress on glass tubes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a straight aluminum baseplate is used in U-shaped or H-shaped tubes, then the assembly process is simplified, but the heat conduction becomes non-uniform and illumination consistency deteriorates
Solution Approach 1:
The baseplate is segmented into multiple independent baseplates, each fitted into separate branches of U-shaped or H-shaped tubes. This segmentation allows each baseplate to be independently optimized for its specific tube branch, ensuring uniform heat conduction and consistent illumination across all LED lamp beads while maintaining simplified assembly through modular construction
Solution Approach 2:
Different baseplates are designed with locally optimized characteristics suitable for their specific tube branches. Each baseplate's dimensions, shape, and thermal properties are tailored to its local requirements, ensuring optimal heat conduction and illumination consistency for each segment while maintaining overall system simplicity
2Illumination intensity
If multiple straight tubes or U-shaped/H-shaped tubes are added to increase illuminance, then the light output is improved, but the bearing rod cannot be uniformly stressed and assembly complexity increases
Solution Approach 1:
The illumination system is divided into multiple independent tube branches, each with its own baseplate and LED array. This segmentation allows the bearing rod to be uniformly stressed across all branches during assembly, as each branch can be independently positioned and secured, while achieving high light output through the combined effect of multiple branches
Solution Approach 2:
Multiple tube branches with identical baseplate designs are combined into a single U-shaped or H-shaped structure. This merging allows uniform stress distribution on the bearing rod during assembly while achieving high illuminance through the cumulative light output of all branches, reducing overall assembly complexity through standardization
3Illumination intensity
If two aluminum baseplates are separately inserted into U-shaped or H-shaped tube branches, then the illumination coverage is improved, but the circuit wiring becomes more complex and cost increases
Solution Approach 1:
The baseplate design incorporates universal electrical connection features that can be applied to both straight and U-shaped/H-shaped tubes. By standardizing the circuit wiring interface and configuration across all baseplates, the system achieves wide illumination coverage through multiple branches while maintaining simple and consistent circuit wiring procedures
Solution Approach 2:
All baseplates are designed with identical electrical connection characteristics and circuit configurations. This homogeneity ensures that circuit wiring remains simple and consistent across all tube branches, even as illumination coverage is expanded through the addition of multiple baseplates and branches
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 solution ensures uniform illumination, reduces production costs, and prevents glass tube damage by allowing for uniform heat conduction and simplified assembly, while maintaining consistent brightness and color across all LED lamp beads.
Implementation Method 1
The heat conductive adhesive is pasted between the two branches and the internal wall of the tube
Data Source
AI summary
This invention provides an integrated LED energy-saving lamp, a manufacturing method thereof and a corn lamp. The LED energy-saving lamp comprises at least one tube, at least one baseplate, a plurality of LED lamp beads and a heat conductive adhesive. Each tube comprises two parallel first parts and a second part for connecting the two first parts. Each baseplate comprises two parallel branch parts, located on the same plane, and a connecting part for connecting with the two branches; the two branches are respectively located in the two first parts of the tube. The LED lamp beads are respectively arranged on the two branches. The heat conductive adhesive is pasted between the two branches and the internal wall of the tube.