Bipartite Capper for LED Retrofit Lamps

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Solution Overview

Problem

Conventional HID lamps experience arcing issues between the lamp base and lampholder, leading to potential damage and safety hazards, which existing solutions like using high-wattage lamps with nickel-plated copper alloy or stainless steel contacts and supplemental coil springs are expensive and not widely implemented.

Innovation Solution

A bipartite capper component with a conductive portion and insulative portion is designed to be threadedly engaged with the metal base, providing high thermal conductivity and structural integrity, and includes a safety bracket to prevent detachment from the lampholder, reducing the risk of arcing and safety hazards.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional HID lamps are used with standard lampholders, then the lamp can be installed and operated, but arcing occurs between the lamp base and lampholder leading to damage and safety hazards

Engineering Contradiction:

Improvearc resistanceVSAvoidarcing damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a capper component as an intermediary element between the lamp base and the lampholder. This capper includes a conductive portion that contacts the lamp base and an insulative portion that contacts the lampholder, thereby mediating the electrical connection and preventing direct arcing between the metal base and metal lamphholder. The insulative portion acts as a barrier that interrupts the harmful electrical discharge path.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The capper component is constructed from composite materials - specifically a combination of conductive material (for the conductive portion) and insulative material (for the insulative portion). This composite structure allows the single component to simultaneously provide both electrical contact and arc prevention functions, resolving the contradiction between needing electrical connection and preventing arcing damage.

Inventive Principle:

Principle #40Composite materials

2Reliability

If high wattage HID lamps with nickel plated copper alloy or stainless steel contacts and supplemental coil springs are used, then contact pressure increases and arcing is reduced, but the cost becomes expensive and implementation is limited

Engineering Contradiction:

Improvecontact stabilityVSAvoidimplementation cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The capper component provides a cost-effective alternative to expensive nickel plated copper alloy or stainless steel contacts with supplemental coil springs. By using a simpler design with conductive and insulative portions, the patent achieves arc prevention functionality at lower cost, making widespread implementation feasible without requiring expensive remedial responses.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent extracts the essential arc prevention function from the complex system of nickel plated contacts and supplemental coil springs, isolating it into a dedicated capper component. This simplification removes unnecessary complexity and cost while maintaining the core functionality of preventing arcing and ensuring contact stability.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If the lamp base is made of conductive metal for electrical contact, then electrical connection is established, but the conductive base is susceptible to arcing damage

Engineering Contradiction:

Improveelectrical conductivityVSAvoidarcing vulnerability

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The capper component segments the electrical connection function from the structural support function. The conductive portion handles electrical contact with the lamp base, while the insulative portion provides structural support and contacts the lampholder. This segmentation allows the metal base to remain conductive for electrical connection while the insulative portion protects against arcing damage by interrupting the electrical discharge path.

Inventive Principle:

Principle #1Segmentation

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 bipartite capper component effectively reduces the risk of structural failure and safety hazards by preventing detachment of the lamp from the holder during arcing events, as demonstrated by comparative testing showing longer arcing times without lamp detachment.

Implementation Method 1

The capper component may include a conductive portion for being threadedly engaged with a metal base of the lamp... It may be desirable for the capper component to have high thermal conductivity.

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

an insulative portion that electrically isolates the conductive portion of the capper component

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS10508776B2Anti-detachment capper for LED retrofit lamps

Publication Date: 2019.12.17 GE LIGHTING SOLUTIONS LLC

AI summary

A bipartite capper component for an illuminating lamp includes a first portion formed of a first material and a second portion formed of a second material different from the first material. The second portion of the capper component is in contact with the first portion of the capper component. The first portion of the capper component is configured to threadedly engage within a standard threaded metal base component of the illuminating lamp.