LED Lamp Substrate with Segmented Protrusions for Downlight
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Solution Overview
Problem
LED-based lamps face challenges in meeting energy efficiency standards, particularly in providing sufficient downlight while maintaining heat management and form factor compatibility with traditional incandescent bulbs.
Innovation Solution
The design incorporates a substrate with alternating recessed and protruding portions to support LEDs, allowing for efficient heat transfer and directing backlight towards the base, combined with a heat sink and optically transmissive enclosure to enhance downlight distribution and maintain a compact form factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If LEDs are mounted on a substrate with alternating recessed and protruding portions, then downlight emission is improved, but device complexity increases
Solution Approach 1:
The substrate is segmented into alternating recessed portions and protruding portions, creating distinct zones for different LED orientations. This segmentation allows specific LEDs to be positioned on protruding portions to direct light downward, thereby improving downlight emission while maintaining a manageable structural complexity through systematic division
Solution Approach 2:
Different regions of the substrate are assigned different functions: protruding portions support LEDs oriented to emit downlight, while recessed portions accommodate other components or differently oriented LEDs. This local differentiation optimizes light distribution characteristics in specific zones without requiring complete redesign of the entire substrate structure
2Temperature
If a heat sink is integrated into the lamp structure, then heat management is improved, but volume of the lamp increases
Solution Approach 1:
The heat sink is merged with the existing lamp structure, integrating thermal management functionality into the housing rather than adding it as a separate component. This combination allows heat dissipation surfaces to be incorporated within the existing volume constraints, improving heat management without proportionally increasing overall lamp volume
Solution Approach 2:
The lamp housing serves multiple functions: it provides structural support, contains the optical components, and simultaneously acts as a heat sink for thermal management. This multi-functionality eliminates the need for additional dedicated heat dissipation structures, maintaining compact dimensions while achieving effective heat management
3Illumination intensity
If the enclosure is made optically transmissive, then light distribution is improved, but heat management becomes more difficult
Solution Approach 1:
The enclosure is segmented into optically transmissive portions for light distribution and thermally conductive portions for heat management. This segmentation allows different regions of the enclosure to fulfill different functions: transparent sections permit light to pass through while metallic or heat-conductive sections provide thermal pathways for heat dissipation
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 increases downlight emission to meet energy efficiency standards while ensuring effective heat management and compatibility with standard bulb sizes, enhancing the overall performance and efficiency of LED lamps.
Implementation Method 1
The substrate may be thermally coupled to a heat sink such that heat from the LEDs is transferred to the exterior of the bulb
Data Source
AI summary
An LED based lamp has an optically transmissive enclosure connected to a base. The base may include a heat sink. A substrate is positioned in the enclosure and supports a plurality of LEDs where the periphery of the substrate has alternating recessed portions and protruding portions that define a plurality of laterally extending projections. One LED is located on each of the projections to increase the amount of down light generated by the lamp.