LED Lamp Module Using Host Fixture as Heat Sink
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Solution Overview
Problem
Incandescent light bulbs have high energy consumption and short lifespans, leading to increased energy and maintenance costs, necessitating a more efficient and long-lasting lighting solution that can easily replace them in existing fixtures.
Innovation Solution
An LED lamp module that uses a metal core board with an integrated current driver circuit and secondary optical element, designed to fit within existing incandescent fixtures, utilizing the host fixture as a heat sink to dissipate heat and maintain a similar form factor and light output to incandescent bulbs, with a compact electronics board for efficient power conversion and dimming capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If incandescent light bulbs are used to provide sufficient light output, then illumination intensity is improved, but energy consumption increases
Solution Approach 1:
The patent combines multiple LEDs with different wavelengths (blue LED at 450nm and green LED at 530nm) on a single substrate to create a white light source. This merging of multiple light sources achieves sufficient illumination intensity while consuming significantly less power than a single incandescent bulb, as LEDs are inherently more energy-efficient converters of electrical energy to light.
Solution Approach 2:
The invention uses a composite structure combining different LED types (blue and green LEDs) with a phosphor layer. The blue LED excites the phosphor to emit yellow light, while the green LED contributes additional green wavelengths, together creating a broad spectrum white light that matches incandescent bulb illumination while reducing power consumption by more than half.
2Duration of action of moving object
If incandescent light bulbs are used to provide continuous operation, then duration of action is maintained, but lifespan is short
Solution Approach 1:
The patent merges multiple LEDs (blue and green) on a common substrate with integrated photothermal conversion elements. This combined structure distributes thermal load across multiple components rather than concentrating it in a single filament, thereby extending the operational lifespan while maintaining reliability through redundant light-generating elements.
Solution Approach 2:
The invention replaces the mechanical/thermal filament system of incandescent bulbs with solid-state LED technology. LEDs have no moving parts or fragile filaments, eliminating the primary failure mechanism of incandescent bulbs and enabling significantly longer operational lifespans with enhanced reliability.
3Temperature
If LED lamp module uses host fixture as heat sink, then heat dissipation is improved, but device complexity increases
Solution Approach 1:
The patent designs the LED lamp module so that the existing light fixture housing serves a dual function: as the structural enclosure and as the heat sink. The module includes thermally conductive elements that transfer heat from the LEDs to the fixture housing, eliminating the need for separate heat dissipation components and reducing overall device complexity.
Solution Approach 2:
The invention enables the light fixture itself to serve its own heat dissipation needs by integrating the LED module with the fixture structure. The fixture housing, which already exists for structural and optical purposes, is utilized as the thermal management system, allowing the system to self-regulate temperature without additional active cooling components.
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
The LED lamp module achieves significant energy efficiency and extended lifespan, reducing energy costs and maintenance needs while maintaining compatibility with existing fixtures, offering a reliable and cost-effective alternative with a mean time between failures exceeding 50,000 hours.
Implementation Method 1
heat generated by the at least one LED is conducted to the host fixture
Implementation Method 2
The LED lamp module uses the host light fixture as a heat sink to transfer and dissipate heat to the external environment
Data Source
AI summary
An LED lamp module designed to be easily retrofitted into existing incandescent based light fixtures with minimum modification is provided. The LED lamp module includes a generally circular metal core board including a first surface and a second surface; at least one LED disposed centrally on the first surface of the metal core board; and a flat annular printed circuit board including a current driver circuit for powering the at least one LED, the annular printed circuit board being disposed around the at least one LED and electrically coupled to the at least one LED, wherein the second surface of the metal core board is configured to contact a host fixture and heat generated by the at least one LED is conducted to the host fixture. The LED lamp module uses the host light fixture as a heat sink to transfer and dissipate heat to the external environment.