LED Lamp Heat Pipe Elevator for Thermal Management
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Solution Overview
Problem
Conventional LED bulbs with omnidirectional emission patterns are complex, expensive, and unreliable, and existing designs fail to optimize heat dissipation, limiting their practicality for wide-scale illumination applications.
Innovation Solution
The development of solid state lamps with thermally conductive elevating elements, such as heat pipes, that mount LEDs above the lamp base, combined with diffusers and heat sinks to manage heat and achieve desired emission patterns, including omnidirectional emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional LED bulbs are designed with omnidirectional emission patterns, then light distribution is improved, but device complexity and cost increase significantly
Solution Approach 1:
The lamp is divided into distinct functional segments: an elevated LED light source module mounted on heat pipes, a separate diffuser component, and a heat sink base. This segmentation allows each component to be optimized independently for its specific function while working together to achieve omnidirectional emission without excessive complexity
Solution Approach 2:
The LED light source is elevated vertically above the lamp base using thermally conductive heat pipes, creating a three-dimensional spatial arrangement. This vertical dimensionality allows light to emit in multiple directions (upward, downward, sideways) naturally, achieving omnidirectional emission patterns without complex optical components
2Reliability
If heat dissipation is not optimized in LED bulbs, then manufacturing is simpler, but LED lifespan and performance are limited
Solution Approach 1:
The heat pipes serve multiple functions simultaneously: they act as thermal conduction paths to transfer heat from LEDs to the heat sink, provide structural support to elevate the LED light source above the base, and contribute to the overall mechanical framework of the lamp. This multi-functionality reduces the need for separate components
Solution Approach 2:
Heat pipes are introduced as intermediary thermal management components between the LED light sources and the heat sink base. These heat pipes efficiently conduct heat away from the LEDs while allowing the LEDs to be positioned optimally for light emission, protecting the LEDs from excessive heat without adding complex active cooling systems
3Productivity
If drive current is increased to boost luminous flux, then light output is improved, but heat generation increases and reduces LED lifespan
Solution Approach 1:
The patent converts the harmful effect of heat generation into a manageable parameter by implementing an efficient passive heat dissipation system using heat pipes and heat sinks. This allows the system to operate at higher drive currents for increased luminous flux output, as the heat is continuously and efficiently transferred away from the LEDs to the surrounding environment
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 enables efficient heat dissipation, increased drive current, and longer LED lifespan, allowing for higher luminous flux and compliance with energy efficiency standards like ENERGY STAR, while reducing complexity and cost, making them suitable replacements for incandescent and fluorescent bulbs.
Implementation Method 1
An elongated elevating element is mounted to the lamp with the light source mounted to the elevating element such that the solid state light source is above the lamp base. The elevating element can be made of a material that is at least partially heat conductive.
Implementation Method 2
The elevating element can be made of a material that is at least partially heat conductive
Implementation Method 3
A diffuser is included to diffuse light emitting from lamp into the desired emission pattern
Data Source
AI summary
LED based lamps and bulbs are disclosed that comprise an elevating element to arrange LEDs above the lamp or bulb base. The elevating element can at least partially comprise a thermally conductive material. A heat sink structure is included, with the elevating element thermally coupled to the heat sink structure. A diffuser can be arranged in relation to the LEDs so at least some light from the LEDs passes through the diffuser and is dispersed into the desired emission pattern. Some lamps and bulbs utilize a heat pipe for the elevating elements, with heat from the LEDs conducting through the heat pipe to the heat sink structure where it can dissipate in the ambient. The LED lamps can include other features to aid in thermal management and to produce the desired emission pattern, such as internal optically transmissive and thermally conductive materials, and heat sinks with different heat fin arrangements.