Modular LED Lamp Base with Plug-in Light Modules
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Solution Overview
Problem
Existing solid state lamps face challenges in heat removal, cost, and environmental impact, particularly when replacing incandescent and compact fluorescent bulbs, due to high power LEDs and permanent electronic components.
Innovation Solution
A modular solid state lamp design featuring a base with plug-in LED modules that allow for adjustable brightness and light distribution, using low-power LEDs spread over a large surface for efficient cooling and reduced material waste, with modules that can be combined for various light patterns and chromaticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high power LEDs are used to achieve desired lumen output with fewer LEDs, then the number of LEDs is reduced, but heat removal becomes difficult and junction temperature control becomes challenging
Solution Approach 1:
The invention divides the light source into multiple low-power LED modules distributed across a large surface area rather than using fewer high-power LEDs. Each module operates at lower current (e.g., 20 mA) and generates less heat, making temperature control easier while collectively achieving the desired lumen output through distributed emission.
Solution Approach 2:
The invention transitions from concentrating LED power in a small area (few high-power LEDs) to distributing them across a large surface area (many low-power LEDs). This dimensional redistribution of light-emitting elements across the bulb surface enables adequate heat dissipation while maintaining total light output.
2Device complexity
If all LEDs are mounted on a relatively small flat substrate, then device complexity is reduced, but light emission distribution becomes non-spherical and creates shadow lines and flux variations
Solution Approach 1:
The invention segments the light-emitting elements into multiple modules distributed across the bulb surface rather than mounting all LEDs on a single flat substrate. This segmentation enables spherical light distribution patterns that eliminate shadow lines and provide uniform illumination, while each module remains relatively simple in structure.
Solution Approach 2:
The invention moves LED mounting from a two-dimensional flat substrate to a three-dimensional distribution across the bulb surface. This spatial redistribution enables spherical emission patterns that match traditional lamp characteristics, improving light distribution while maintaining manufacturing simplicity through modular designs.
3Temperature
If metal fins or heavy metal heat sinks are used to remove heat, then heat removal efficiency is improved, but cost and weight increase significantly
Solution Approach 1:
The invention uses multiple low-power LED modules distributed across a large surface area, which naturally dissipate heat more efficiently due to greater surface area and lower individual power dissipation. This eliminates the need for heavy metal heat sinks, reducing both weight and cost while maintaining adequate heat removal.
Solution Approach 2:
The invention converts the potential harm of heat generation into a benefit by using many low-power LEDs that naturally dissipate heat through their distributed configuration. The large surface area and low individual power consumption of each module turn the heat management challenge into an advantage, eliminating the need for additional heavy cooling components.
4Device complexity
If the electronic ballast is permanently joined to the fluorescent tube, then device complexity is reduced, but the entire lamp must be discarded when the tube fails, increasing waste
Solution Approach 1:
The invention segments the lamp into a permanent base containing the electronic ballast and replaceable LED modules. When LED modules fail, only the modules need replacement while the base remains in use, reducing waste. This segmentation maintains simple assembly through standardized receptacles while enabling component reuse.
Solution Approach 2:
The invention enables recovery and reuse of the electronic ballast and base structure by allowing replacement of only the LED modules. When modules fail, they are discarded and replaced, while the valuable electronic components and structural base are retained and reused, significantly reducing material waste compared to permanent joining designs.
5Adaptability or versatility
If a single base design is used for various brightness levels, then adaptability is improved, but the ability to satisfy differing consumer needs is reduced
Solution Approach 1:
The invention segments the light output control into replaceable LED modules that can be configured in different quantities and arrangements within a single base. Consumers can select modules providing different brightness levels (e.g., 40W, 60W equivalents) by choosing appropriate module configurations, maintaining base compatibility while satisfying diverse lighting needs.
Solution Approach 2:
The invention enables dynamic adaptation of brightness levels through replaceable LED modules that can be configured to provide different lumen outputs. The base structure remains static and compatible, while the modular LED components can be changed to match varying consumer requirements, providing both adaptability and product variety.
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 modular design achieves efficient heat dissipation without significant added cost or weight, reduces environmental impact by allowing component reuse, and provides customizable light output that emulates traditional bulbs, improving efficiency and adaptability.
Implementation Method 1
a solid state lamp whose light output is selectable and replaceable... using light emitting diodes (LEDs)... Each plug-in module may be a flat module containing an array of LEDs connected in series
Implementation Method 2
The base may be formed of ceramic or other type of thermally conductive insulating material
Data Source
AI summary
A solid state lamp, such as one that can replace an incandescent light bulb, has a base portion having an electrical connector for connection to a source of power, such as an Edison-type connector for connection to the mains voltage. An AC/DC converter in the base converts the mains voltage to a suitable light emitting diode (LED) drive voltage. A plurality of receptacles on the base connects to electrodes of plug-in modules. Each plug-in module supports a plurality of low power LEDs connected in series. The strings of LEDs on different modules are connected in parallel when connected to the receptacles. The modules and base are configured to allow a user to operate the lamp with different combinations of modules to generate a desired light output from the lamp. For example, the user can recreate the lumens equivalent of a 20 W, 40 W, or 60 W bulb by using one, two, or three modules.