LED Lamp Heat Sink Nesting for Thermal Management
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Solution Overview
Problem
Conventional LED lighting systems face challenges in efficiently dissipating heat and maintaining a compact form factor, leading to reduced lumen output and increased heat-related losses, which affects their performance and compatibility with traditional incandescent bulb form factors.
Innovation Solution
The design incorporates an optically transmissive enclosure with a heat sink that thermally couples to the LED assembly, positioning the LEDs at the optical center to maximize light transmission and using a boost converter topology power supply to minimize energy losses, while a primary reflector directs light to achieve a desired beam angle, allowing for a smaller heat sink and omnidirectional or directional light patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If LED assembly is positioned at the optical center of the enclosure, then light transmission efficiency is maximized, but heat dissipation becomes more difficult due to limited space for heat sink
Solution Approach 1:
The heat sink is nested within the enclosure structure, with its base positioned at the bottom of the enclosure and its body extending upward while remaining contained within the enclosure boundaries. This nesting approach allows the heat sink to be integrated into the compact lamp design without requiring external space, thereby enabling both optimal LED positioning for light transmission and adequate heat dissipation within the same confined volume.
2Volume of moving object
If heat sink size is reduced to maintain compact form factor, then compatibility with traditional bulb form factors is improved, but heat dissipation efficiency decreases leading to increased heat-related losses
Solution Approach 1:
The heat sink employs locally optimized thermal conduction pathways with high thermal conductivity material in the base region directly contacting the LED assembly, ensuring efficient heat extraction at the heat generation point. The heat sink body is designed with varying cross-sectional areas and surface textures at different locations to maximize heat dissipation efficiency within the constrained volume, thereby reducing heat-related losses while maintaining compact dimensions.
3Loss of energy
If LED assembly is positioned away from the optical center to improve heat dissipation, then heat-related losses are reduced, but light transmission efficiency and lumen output decrease
Solution Approach 1:
The heat sink is nested within the enclosure structure, with its base positioned at the bottom of the enclosure and its body extending upward while remaining contained within the enclosure boundaries. This nesting approach allows the heat sink to be integrated into the compact lamp design without requiring external space, thereby enabling both optimal LED positioning for light transmission and adequate heat dissipation within the same confined volume.
4Use of energy by moving object
If conventional LED lighting systems are used, then energy efficiency is improved compared to incandescent, but heat dissipation challenges remain leading to reduced performance
Solution Approach 1:
The heat sink employs locally optimized thermal conduction pathways with high thermal conductivity material in the base region directly contacting the LED assembly, ensuring efficient heat extraction at the heat generation point. The heat sink body is designed with varying cross-sectional areas and surface textures at different locations to maximize heat dissipation efficiency within the constrained volume, thereby reducing heat-related losses while maintaining compact dimensions.
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 configuration enhances light efficiency, reduces heat generation, and maintains a compact size, enabling the LED lamp to match the form factor of traditional bulbs while providing consistent lumen output with minimal heat-related losses.
Implementation Method 1
a packaged heat sink that is thermally coupled to the LED assembly
Implementation Method 2
An optically transmissive enclosure is provided and a packaged heat sink is positioned in the optically transmissive enclosure
Implementation Method 3
a primary reflector that is positioned inside of the optically transmissive enclosure and that reflects light generated by the LED assembly
Data Source
AI summary
A lamp has an optically transmissive enclosure and a base. A tower extends from the base into the enclosure and supports an LED assembly in the enclosure. The LED assembly comprises a plurality of LEDs operable to emit light when energized through an electrical path from the base. The tower and the LED assembly are arranged such that the plurality of LEDs are disposed about the periphery of the tower in a band and face outwardly toward the enclosure to create a source of the light that appears as a glowing filament. The tower forms part of a heat sink that transmits heat from the LED assembly to the ambient environment. The LED assembly has a three-dimensional shape. An electrical interconnect connects a conductor to the heat sink where the conductor is in the electrical path between the LED assembly and the base.