Curved LED Lamp with 3D Junction Array
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Solution Overview
Problem
Existing lighting solutions using light emitting diodes (LEDs) are not suitable for providing quality domestic or industrial lighting, as they often lack the necessary luminosity and uniformity, and existing methods of mounting LEDs are complex and inefficient.
Innovation Solution
A method of producing a lamp with a three-dimensional array of light emitting junctions mounted on a curved electrically conductive support structure, where the junctions are placed in respective receptacles and electrically connected to ensure predictable and repeatable light patterns, with the receptacles being singularized and securely attached to the lead frame using welding, soldering, or gluing for enhanced mechanical, thermal, and electrical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a three-dimensional array of light emitting junctions is mounted on a curved support structure, then luminosity and uniformity are improved, but device complexity increases
Solution Approach 1:
The support structure is divided into multiple receptacles that can individually hold light emitting junctions, allowing the system to be constructed from modular units. This segmentation enables the creation of a three-dimensional array while maintaining manageable complexity through standardized repeating elements.
Solution Approach 2:
The patent transitions from traditional two-dimensional LED arrays to a three-dimensional configuration by mounting receptacles on a curved support structure. This dimensional change increases luminosity and uniformity by distributing light sources in multiple spatial dimensions, creating more comprehensive illumination coverage.
2Illumination intensity
If a three-dimensional array of light emitting junctions is mounted on a curved support structure, then uniformity of light output is improved, but manufacturing complexity increases
Solution Approach 1:
The support structure incorporates multiple identical receptacles that can be manufactured as standardized components. This segmentation into modular units simplifies the manufacturing process by allowing mass production of identical receptacle-junction assemblies, which are then integrated into the final three-dimensional array.
Solution Approach 2:
Light emitting junctions are pre-mounted into receptacles before the receptacles are installed onto the curved support structure. This preliminary action allows for standardized pre-assembly of junction-receptacle units, simplifying the final assembly process and improving manufacturing efficiency while maintaining the complex three-dimensional configuration.
3Strength
If receptacles are securely attached to the lead frame using welding or soldering, then mechanical strength and electrical connectivity are improved, but manufacturing time increases
Solution Approach 1:
The patent combines mechanical attachment and electrical connection functions into a single integrated process. By using welding or soldering to simultaneously secure the receptacle to the lead frame and establish electrical connectivity, the invention eliminates the need for separate mechanical and electrical connection steps, thereby improving both strength and electrical performance without proportionally increasing manufacturing time.
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 approach simplifies the manufacturing process, allows for modular mounting of LEDs, and provides a lamp with improved luminosity and uniformity, enabling efficient and predictable light output suitable for various applications.
Implementation Method 1
Lighting applications involving the use of light emitting diodes (LEDs)
Implementation Method 2
light emitting junctions disposed in respective receptacles and electrically connected to the support structure
Implementation Method 3
The array of cups so placed in the lead frame are restrained in their respective holes... such that the combined light pattern from a three dimensional array of cups on a lead frame is predictable and repeatable
Data Source
AI summary
A method of producing a lamp, including: mounting light emitting junctions in respective receptacles; mounting the receptacles on a curved support structure so as to form a three-dimensional array; and placing the light emitting junctions in electrical connection with the support structure.