LED Light Bar Installation via Thermal Deformation

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Solution Overview

Problem

The challenge is to effectively manage heat dissipation and light distribution in LED light bulbs to enhance luminous efficiency and extend the service life, as traditional methods often fail to address heat accumulation and uniform lighting.

Innovation Solution

The method involves installing a light-emitting diode (LED) light bar within a bulb shell using an expansion structure, such as an inflatable balloon, to deform the LED light bars and secure them against the shell, allowing for improved heat dissipation and customizable light distribution through strategic placement of LED cores and cooling elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If LED light bars are installed in traditional bulb shells with narrow neck portions, then the bulb can maintain traditional shapes and sizes, but the LED light bars cannot be properly positioned and cooled against the bulb shell

Engineering Contradiction:

Improvebulb shell shapeVSAvoidheat dissipation effectiveness

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent employs a dynamic installation process where the bulb shell is temporarily softened by heating, allowing the narrow neck portion to expand. This enables the LED light bar to be positioned against the bulb shell interior, and upon cooling, the shell returns to its original shape, securing the LED in place while maintaining effective thermal contact

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes the physical parameter of the bulb shell material by heating it to a temperature where the material becomes soft and deformable. This temporary parameter change allows the shell structure to be modified for LED installation, then returns to its original state upon cooling, achieving both traditional shape preservation and effective LED positioning

Inventive Principle:

Principle #35Parameter changes

2Reliability

If LED light bars are deformed and expanded to contact the bulb shell for heat dissipation, then heat dissipation efficiency improves, but the installation process becomes more complex

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidinstallation process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical deformation and securing mechanisms with a thermal field-based installation method. By using heat to temporarily soften the bulb shell material, the LED light bar can be easily positioned and secured through material property changes rather than mechanical fastening or deformation systems

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The bulb shell material itself provides the installation mechanism through its temperature-dependent properties. The shell softens when heated to allow LED positioning, then automatically secures the LED upon cooling without requiring additional mechanical fastening components or complex installation tools

Inventive Principle:

Principle #25Self-service

3Illumination intensity

If multiple LED cores are placed strategically in the light bar, then light distribution uniformity improves, but the light bar width increases making installation through narrow neck portions difficult

Engineering Contradiction:

Improvelight distribution uniformityVSAvoidlight bar width

Core Design Contradiction:

Illumination intensityVSLength of moving object

Solution Approach 1:

The patent uses the dynamic property of the bulb shell material (softening when heated) to enable installation of wider LED light bars that contain multiple LED cores for improved light uniformity. The temporary expansion of the shell neck during heating allows the wider light bar to be inserted, then the shell returns to its original shape to secure the light bar in place

Inventive Principle:

Principle #15Dynamics

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 approach enhances heat dissipation and light distribution, leading to increased luminous efficiency and extended service life by ensuring efficient heat diffusion and maintaining optimal temperature levels around the LED light bars.

Implementation Method 1

Every LED light bar has a certain bending property. In other words, these LED light bars can be deformed by an external force.

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

The substrate mentioned herein may be made of glass material, aluminum material, alloy material, plastic material, or other various materials.

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10247364B2Method for installing LED light bar into light bulb and device

Publication Date: 2019.04.02 XIAMEN ECO LIGHTING CO LTD

AI summary

A method for installing a LED light bar into a light bulb. First, place a light module into bulb shell. The light bar module has a plurality of LED light bars and expansion structure. The expansion structure is unexpanded and disposed between the plurality of LED light bars. Each LED light bar has a certain bending property. Expending the expansion structure could make the plurality of LED light bars bent to the direction of bulb shell individually. And then, remove the expansion module and install the other components of the bulb.