LED Tube Inner Surface Mounting Heat Dissipation
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Solution Overview
Problem
Existing LED lighting tubes face challenges with costly and complex construction due to suspended LED assemblies, limited light arc due to supporting structures, and difficulty in using durable materials like thin glass or brittle plastic, as well as inadequate mechanical protection and inconsistent light diffusion.
Innovation Solution
An LED lighting tube design where the LED assembly is directly affixed to the inner surface of a heat-dissipating tubular envelope using an adhesive layer, eliminating the need for a heat sink and providing a wider light arc, along with a light-diffusing and protective film for consistent application and mechanical protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the LED assembly is attached to supports suspended from end caps or interior of envelope, then the LED assembly is held in place, but the construction becomes costly and difficult to align during shipping and installation
Solution Approach 1:
The patent removes the supporting structures (end caps, suspension systems) that were previously necessary to hold the LED assembly in place. Instead, the LED assembly is directly mounted to the envelope itself, eliminating the intermediate supporting components and simplifying the overall device structure while maintaining proper positioning.
Solution Approach 2:
The patent combines the functions of the envelope and the mounting structure into a single integrated component. The envelope serves both as the protective housing and as the mounting surface for the LED assembly, eliminating the need for separate supporting structures and reducing device complexity.
2Temperature
If supporting structures, circuit board, and heat sink are present, then the LED assembly is supported and heat is dissipated, but the arc of illumination is limited due to light blocking
Solution Approach 1:
The patent removes the heat sink component that was previously blocking light. Instead, the envelope itself serves as the heat dissipation structure, allowing light to pass through the transparent or translucent envelope material without being blocked by an external heat sink, thereby increasing the arc of illumination while maintaining heat dissipation functionality.
Solution Approach 2:
The envelope is given multiple functions: it serves as the protective housing, the mounting surface for the LED assembly, and the heat dissipation structure. This eliminates the need for a separate heat sink that would block light, as the envelope performs both the structural and thermal management functions while allowing light transmission.
3Temperature
If the LED assembly interrupts the circumference of the tubular envelope with heat sink outside, then heat is dissipated, but delicate envelope materials like thin glass or brittle plastic cannot be durably attached
Solution Approach 1:
The patent integrates the mounting surface directly into the envelope structure, allowing delicate materials like thin glass or brittle plastic to be securely attached to the envelope's inner surface. The LED assembly is mounted within the envelope rather than interrupting its circumference, providing durable attachment while maintaining the integrity of delicate envelope materials.
4Illumination intensity
If frosted film is applied to diffuse light, then light harshness is reduced, but mechanical protection for the envelope is not provided
Solution Approach 1:
The patent uses a frosted film material that combines both light diffusion and mechanical protection properties in a single layer. This composite approach allows the film to serve dual functions: diffusing light to reduce harshness while simultaneously providing mechanical protection for the envelope, eliminating the need for separate protective 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 solution results in a robust, simple, and broadly illuminating LED lighting tube with a wider light arc of up to 330°, reduced complexity, and enhanced safety through the elimination of a heat sink and supporting hardware, while also providing mechanical protection and uniform light diffusion.
Implementation Method 1
affixing an LED assembly directly to an inner surface of the heat-dissipating tubular envelope with an adhesive layer
Implementation Method 2
dissipating heat through the heat-dissipating tubular envelope
Data Source
AI summary
An LED lighting tube including a heat-dissipating tubular envelope having an LED assembly directly affixed to an inner surface of the heat-dissipating tubular envelope. A method of making an LED lighting tube by providing a heat-dissipating tubular envelope and affixing an LED assembly directly to an inner surface of the heat-dissipating tubular envelope with an adhesive layer. A method of providing heat-dissipation without a heat sink in an LED lighting tube by providing a heat-dissipating tubular envelope, affixing an LED assembly directly to an inner surface of the heat-dissipating tubular envelope with an adhesive layer, and dissipating heat through the heat-dissipating tubular envelope.