LED Filament Bulb Heat Dissipation via Segmented Core Column
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Solution Overview
Problem
LED light bulbs face challenges with heat dissipation, leading to reduced lifespan and stability, and the production of LED bulbs resembling incandescent bulbs often results in weak structures and complex assembly.
Innovation Solution
The LED filament bulb apparatus features a bulb shell, LED strips with substrates, a core column, pluggable sockets, a driver board, and a cap, with innovative designs for heat dissipation, such as embedded power lead wires and a heat sink, and elastic receiver parts for secure power connections, enhancing manufacturing efficiency and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If LED bulbs are designed to resemble traditional incandescent bulbs in appearance, then aesthetic similarity is improved, but structural strength deteriorates and assembly complexity increases
Solution Approach 1:
The bulb is divided into functionally independent modules: a bulb shell for aesthetic appearance, a separate core column for structural support, LED strips for lighting function, and a driver board for control. This segmentation allows each component to be optimized independently - the bulb shell maintains incandescent-like aesthetics while the core column provides robust structural support.
Solution Approach 2:
The core column acts as an intermediary structural element that connects the bulb shell to the internal components. It provides mechanical support and houses the power lead wires, separating the aesthetic function of the bulb shell from the structural and electrical functions, thereby resolving the conflict between appearance and strength.
2Shape
If LED bulbs are designed to resemble traditional incandescent bulbs in appearance, then aesthetic similarity is improved, but assembly complexity increases
Solution Approach 1:
By segmenting the bulb into pre-assembled modules (bulb shell, core column with embedded wires, LED strip assemblies, driver board), the overall assembly process is simplified. Each module can be manufactured and tested independently before final integration, reducing assembly complexity despite the intricate internal structure required for aesthetic similarity.
Solution Approach 2:
The core column is prepared in advance with power lead wires embedded during manufacturing. The LED strips are pre-attached to substrates with electrodes. These preliminary actions during component manufacturing reduce the complexity of final assembly, as connections are largely pre-established rather than requiring complex wiring during bulb assembly.
3Reliability
If heat dissipation is not effectively managed, then LED lifespan and stability deteriorate, but heat dissipation structures increase device complexity
Solution Approach 1:
The driver board, which generates significant heat during operation, is extracted and positioned outside the bulb shell on the cap or base. This separates the heat-generating component from the LED lighting chamber, improving heat dissipation without requiring complex internal heat management structures within the bulb itself.
Solution Approach 2:
The core column serves multiple functions: it provides structural support for the bulb, houses and protects the power lead wires, and acts as a thermal management pathway. By making the core column multi-functional, heat dissipation is achieved without adding separate dedicated heat dissipation structures, thus avoiding increased device complexity.
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 improves the reliability and cost-effectiveness of LED bulbs by enhancing heat dissipation, stability, and assembly processes, while maintaining aesthetic similarity to incandescent bulbs.
Implementation Method 1
LED (Light emitting diode) technology
Implementation Method 2
multiple LED chips disposed on the substrate connected in series or in other manner
Implementation Method 3
If the problems of heat dissipation can be solved effectively, the life span of LED and the stability of light fixtures would be greatly improved
Data Source
AI summary
A LED filament bulb apparatus includes a bulb shell, one or more LED strips, a core column, two pluggable sockets, a driver board and a cap. The LED strip is electrically connected to two power lead wires. The core column supports the LED strip. The two power lead wires have bottom ends. The two pluggable sockets respectively receives the two bottom ends. The driver board is used for mounting the two pluggable socket and a driver circuit. The two bottom ends of the two power lead wires are electrically connected to the driver circuit for receiving a driving current generated by the driver circuit from converting an external power source. The cap is fixed to the core column and the bulb shell.