Omnidirectional LED Light Wire Heat Dissipation

Resolve Bottlenecks,
Find Innovative Solutions
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Solution Overview

Problem

Existing flexible filaments, particularly those using FPC substrates, suffer from low efficacy, low temperature resistance, and poor heat dissipation, leading to a short service life.

Innovation Solution

An omnidirectional LED light wire is developed with multiple flip chips connected through conductive components in various configurations, including series, parallel, or combinations, and a protective layer, which includes a phosphor, to enhance electrical connections and heat dissipation, and is packaged using methods like solder paste or welding processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If FPC substrate is used for flexible filament, then flexibility and ease of manufacture are improved, but efficacy, temperature resistance and heat dissipation deteriorate

Engineering Contradiction:
Improveease of manufactureVSAvoidtemperature resistance
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The patent removes the FPC substrate from the LED structure, extracting the problematic component that caused poor heat dissipation and low temperature resistance. The LED chip is mounted directly on the heat dissipation component, eliminating the thermal bottleneck introduced by the FPC substrate while maintaining manufacturing simplicity through direct mounting techniques.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs composite material structures by combining the LED chip with a specialized heat dissipation component that integrates multiple functional layers. This composite structure incorporates materials with high thermal conductivity for heat dissipation while maintaining electrical insulation and mechanical strength, thereby achieving high temperature resistance without sacrificing ease of manufacture.

Inventive Principle:
Principle #40Composite materials

2Ease of manufacture

If FPC substrate is used for flexible filament, then flexibility and ease of manufacture are improved, but heat dissipation deteriorates

Engineering Contradiction:
Improveease of manufactureVSAvoidheat dissipation
Core Design Contradiction:
Ease of manufactureVSTemperature

Solution Approach 1:

The FPC substrate is extracted and removed from the structure, eliminating its detrimental effect on heat dissipation. The LED chip is directly mounted on the heat dissipation component, creating a direct thermal pathway that significantly improves heat dissipation performance while keeping the manufacturing process simple through direct bonding techniques.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical FPC substrate structure with a direct thermal conduction system. Instead of relying on the FPC's mechanical support function, the design uses a dedicated heat dissipation component with high thermal conductivity materials and direct thermal contact interfaces, substituting the mechanical support system with an optimized thermal management system that achieves superior heat dissipation.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If FPC substrate is used for flexible filament, then flexibility and ease of manufacture are improved, but service life deteriorates

Engineering Contradiction:
Improveease of manufactureVSAvoidservice life
Core Design Contradiction:
Ease of manufactureVSDuration of action of stationary object

Solution Approach 1:

The FPC substrate is extracted and removed from the LED structure, eliminating the source of premature failure. By directly mounting the LED chip on the heat dissipation component, the design removes the thermal stress and degradation mechanisms associated with FPC substrates, thereby extending the service life of the flexible filament while maintaining ease of manufacture through direct bonding processes.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent uses composite material construction with high-temperature-resistant and high-stability materials in the heat dissipation component and sealing structure. This composite approach creates a more durable assembly that resists thermal cycling degradation and extends operational life, while the modular design maintains ease of manufacture through standardized mounting procedures.

Inventive Principle:
Principle #40Composite materials

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 high efficacy, high temperature resistance, and a long service life, addressing the bottlenecks of heat dissipation and temperature resistance in existing FPC substrates, while allowing for adaptable design and improved light transmittance.

Implementation Method 1

a first protective layer which is transparent, translucent or opaque and is covered on a side of the one or more than one flip chips; wherein the protective layer includes or not includes a phosphor

Methodology Applied
Scientific EffectPhotoluminescence: Photoluminescence

Implementation Method 2

the one or more than one flip chips is connected through the two or more than two conductive components to realize an electrical connection relationship

Methodology Applied
Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 3

break bottlenecks of temperature resistance and heat dissipation of the FPC substrate

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11393966B2Omnidirectional LED light wire and packaging method thereof, light source and lamp
Publication Date: 2022.07.19 HANGZHOU HANGKE OPTOELECTRONICS CO LTD
  • US11393966B2 patent drawing
  • US11393966B2 patent drawing
  • US11393966B2 patent drawing

AI summary

An omnidirectional LED light wire and a packaging method thereof, a light source and a lamp, and in particular, to the technical field of LED lighting. The omnidirectional LED light wire includes one or more than one flip chip and two or more than two conductive components. The one or more than one flip chip is connected through the conductive components to realize an electrical connection relationship, in single, in series, parallel or a combination of series and parallel, of the one or more than one flip chip. In view of technical problems of low efficacy, low temperature resistance and poor heat dissipation of the existing FPC substrate, the disclosure breaks bottlenecks of temperature resistance and dissipation of the FPC substrate.