LED Filament Module Heat Dissipation and Structural Stability

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Solution Overview

Problem

LED lighting devices face challenges with heat dissipation, leading to reduced lifespan and stability, and the production of LED light bulbs resembling incandescent bulbs is complicated and results in weak structures.

Innovation Solution

The design includes a filament module with multiple LED chips, a phosphor film, and extended electrodes connected to a substrate, where the top electrodes are fixed together and connected to a pillar, and a driver circuit, with an insulation part to prevent short circuits, and a manufacturing method that simplifies assembly and improves stability by using metal or plastic components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If LED light bulbs are designed to resemble traditional incandescent light bulbs, then aesthetic appeal is maintained, but structural strength becomes weak and assembly becomes complicated

Engineering Contradiction:

Improveaesthetic appealVSAvoidstructural strength

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The bulb is divided into distinct functional modules: a base module containing the driver circuit and heat dissipation structure, and a filament module containing the LED chips arranged in a filament-like configuration. This segmentation allows each module to be optimized independently - the base provides structural strength and heat management, while the filament module provides the desired aesthetic appearance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A support structure acts as an intermediary element connecting the base module to the filament module. This support structure provides mechanical strength and stability to hold the filament modules in position, while being integrated into the overall aesthetic design. The support structure mediates between the functional requirements of structural integrity and the aesthetic requirements of the filament appearance.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Shape

If LED light bulbs are designed to resemble traditional incandescent light bulbs, then aesthetic appeal is maintained, but assembly process becomes complicated

Engineering Contradiction:

Improveaesthetic appealVSAvoidassembly process

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The filament modules are pre-assembled with their support structures and electrical connections before being integrated into the base module. This preliminary assembly simplifies the final integration process, as the filament modules can be installed as complete units rather than assembling individual components during final assembly.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If heat dissipation problems are not solved effectively, then LED lifespan and stability are reduced

Engineering Contradiction:

ImproveLED lifespanVSAvoidheat dissipation

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The heat dissipation function is extracted as a separate, dedicated component - a heat dissipation structure integrated into the base module. This structure is specifically designed to conduct and dissipate heat away from the LED chips, preventing heat accumulation that would reduce LED lifespan and stability. By separating the heat dissipation function from other functions, the design ensures effective thermal management.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The base module acts as an intermediary between the filament modules (heat sources) and the external environment. It contains the heat dissipation structure that mediates heat transfer, conducting heat away from the LEDs and dissipating it through the base, thereby protecting the LEDs from excessive temperature while maintaining the desired aesthetic appearance.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enhances the stability and conductivity of LED lighting devices, improves heat dissipation, and reduces production costs by simplifying the assembly process while maintaining the aesthetic appeal of traditional incandescent bulb designs.

Implementation Method 1

The phosphor film covers the substrate and multiple LED chips

Methodology Applied

Scientific EffectPhotoluminescence: Photoluminescence

Implementation Method 2

A driver circuit electrically connects to multiple bottom extended electrodes of the filaments of the filament module

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS11448370B2LED light bulb

Publication Date: 2022.09.20 XIAMEN ECO LIGHTING CO LTD

AI summary

The lighting device includes at least one filament module, a base, at least one pillar, and a base. The filament module includes more than two filaments. Each filament includes a substrate, multiple LED chips, a phosphor film, a top extended electrode, and a bottom extended electrode. Multiple LED chips are mounted on the substrate. The phosphor film covers the substrate and multiple LED chips. The top extended electrode and bottom extended electrode are connected to two ends of the substrate respectively. At least part of top extended electrode and bottom extended electrode are not covered by the phosphor film, and each top extended electrode of the filaments is fixed together.