Conductive Driver Board for Light Bulb Automated Assembly
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Solution Overview
Problem
Conventional LED light bulbs face challenges in aligning flexible wires during automated assembly, leading to increased production time and cost due to the use of precision formed mechanical contacts.
Innovation Solution
The use of a screw shell with a conductive foam insert and a driver board with legs allows for automated assembly of the light bulb, providing a cost-effective and simplified method to connect line voltage to the driver board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If flexible wires are used to transfer current from supply to driver board, then ease of connection is improved, but manufacturing alignment precision deteriorates
Solution Approach 1:
The patent uses a flexible printed circuit board (FPC) as the connection medium between the supply and driver board. The FPC maintains flexibility for easy connection while providing a rigid enough structure for automated assembly and precise alignment, resolving the contradiction between ease of connection and manufacturing precision.
2Manufacturing precision
If precision formed mechanical contacts are used to transfer line voltage to driver board, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the complex precision-formed mechanical contact components from the design and replaces them with a simplified FPC-based connection system. The FPC provides sufficient electrical connection without requiring the complex precision components, thereby reducing device complexity and cost while maintaining adequate manufacturing precision.
Solution Approach 2:
The patent employs cost-effective FPC materials and construction methods instead of expensive precision-formed mechanical contacts. The FPC provides a economical solution that achieves the necessary functional performance without the high cost associated with precision mechanical contact components.
3Manufacturing precision
If manual assembly of wires is used, then wire positioning accuracy is improved, but productivity decreases
Solution Approach 1:
The FPC is pre-formed with precise trace patterns and connection points before assembly. This preliminary fabrication of the circuit pattern ensures positioning accuracy is achieved during manufacturing rather than during final assembly, enabling automated high-speed assembly without sacrificing precision.
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 enables efficient, automated assembly of LED light bulbs, reducing production time and costs while maintaining electrical continuity, and simplifying the design.
Implementation Method 1
a conductive foam insert and a driver board with legs allows for automated assembly of the light bulb, providing a cost-effective and simplified method to connect line voltage to the driver board
Data Source
AI summary
A light bulb is disclosed, and includes a screw shell defining a cavity, a screw shell insulator, and a driver board. The screw shell insulator defines a passageway that terminates in an aperture. The driver board includes a positive leg that projects from a proximal edge of the driver board, with a proximal end portion that protrudes outside of the aperture, and a negative leg that projects from the proximal edge of the driver board, with a proximal end portion that is electrically connected to the screw shell. The positive leg is configured to extend through the passageway to make electrical contact with a positive terminal of a light socket. Variants in which a base shell and the legs are configured for bayonet type, multifaceted reflector, and T8-like bases are also disclosed.