Thermal Optical Diffuser for LED Bulb Heat Dissipation
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Solution Overview
Problem
Current LED light bulb designs are limited to 60 Watt-equivalent luminosity due to thermal management issues, as they rely on heat sinks on the backside, leading to high temperatures, reduced efficiency, and shortened lifespan, hindering their ability to replace 75 W and 100 W incandescent bulbs.
Innovation Solution
The integration of a thermally conductive base with a thermal optical diffuser and condenser array that allows heat dissipation from the light emitting side, utilizing a large surface area for convective airflow and optical elements to focus light, enabling efficient heat removal without compromising light transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat sinks are used on the backside of LED bulbs to remove heat, then thermal management is improved, but the heat rejection area is constrained to the region behind the LED, leading to high temperatures and reduced efficiency
Solution Approach 1:
The patent introduces a side-mounted heat sink structure that extends laterally from the bulb body, utilizing the side dimension for heat rejection. This allows heat to be dissipated from multiple surfaces (backside and sides) rather than being constrained to the backside only, effectively increasing the heat rejection area without increasing the bulb's overall length.
2Adaptability or versatility
If the light source is tightly packed into a small form factor to maintain incandescent compatibility, then ease of adoption is improved, but thermal management becomes challenging due to limited surface area
Solution Approach 1:
The patent integrates the heat sink structure within the overall bulb form factor, nesting the thermal management components inside the compact housing. The side-mounted heat sink is incorporated into the bulb's side wall structure, allowing efficient heat dissipation while maintaining the standard incandescent bulb dimensions and appearance for seamless replacement.
3Illumination intensity
If more LED assemblies are added to increase luminosity, then light output is improved, but heat generation increases, requiring more complex thermal management
Solution Approach 1:
The patent divides the heat dissipation function into multiple independent heat sink structures mounted on different sides of the bulb. Each heat sink handles thermal load from specific LED assemblies, allowing modular scaling of luminosity while maintaining effective heat management through distributed thermal pathways.
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 solution allows for the development of LED bulbs with luminosity exceeding 100 W equivalent, enhancing adoption and reducing electrical demand by maintaining lower operating temperatures and extending device lifespan.
Implementation Method 1
A subassembly for a light emitting diode (LED) light bulb includes a thermal optical diffuser... The thermal optical diffuser comprises a material having a thermal conductivity greater than about 100 W/(mK)
Implementation Method 2
The thermal optical diffuser and the array of optical elements are arranged to allow convective air flow between the interior volume of the thermal optical diffuser and ambient environment
Implementation Method 3
An array of optical elements is disposed within the interior volume and is configured to focus the emitted light toward the openings
Data Source
AI summary
An LED light bulb includes a thermally conductive base and at least one LED assembly disposed on the base. The LED assembly includes at least one LED configured to emit light. A thermal optical diffuser defines an interior volume of the LED light bulb. The LED is arranged to emit light into the interior volume and through the thermal optical diffuser. The thermal optical diffuser extends from the base to a terminus on a light emitting side of the LED assembly. The thermal optical diffuser includes one or more openings. An array of optical elements is disposed within the interior volume and is configured to focus the emitted light toward the openings. The thermal optical diffuser and the array of optical elements are arranged to allow convective air flow between the interior volume of the thermal optical diffuser and ambient environment.