White-Coated LED Filament Layer for Stable Color and Simpler Bulbs
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Solution Overview
Problem
The existing production process of white coated LED filament bulbs is complex, costly, and the white coated layer on the glass shell is unstable, leading to color bleaching and unstable photoelectric parameters.
Innovation Solution
A white coated LED filament with a white coated layer on the surface of the filament body, using materials like silica gel or epoxy resin glue and titanium dioxide, and a simplified production process involving painting and drying steps to form a stable white coated layer directly on the filament.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If white coated powder is painted on the internal surface of the glass shell, then the glass shell achieves white coating, but the production process becomes complicated and costly
Solution Approach 1:
Instead of coating the glass shell internally with white powder, the patent inverts the approach by coating the LED filament externally. The filament is wrapped with a coating layer containing white coated powder (titanium dioxide, barium sulfate, or calcium carbonate) mixed with adhesive, which is then cured to form a stable white coated layer directly on the filament surface.
Solution Approach 2:
The patent combines the coating application and filament assembly into a single integrated process. The coating layer is applied directly to the filament surface and cured in one step, merging what were previously separate operations (coating the glass shell and assembling the filament) into a unified manufacturing process.
2Reliability
If white coated powder is painted on the internal surface of the glass shell, then the glass shell achieves white coating, but the white coated layer becomes unstable and prone to color bleaching
Solution Approach 1:
The patent inverts the coating location from the glass shell interior to the filament exterior. This positional inversion places the white coated layer in direct contact with the LED light source, allowing it to maintain stability while effectively managing color rendering and preventing color bleaching issues.
Solution Approach 2:
The coating layer is formulated as a composite material combining white coated powder (titanium dioxide, barium sulfate, or calcium carbonate) with adhesive (epoxy resin, silicone resin, or polyurethane). This composite structure provides both the white coating function and the stability needed to prevent color bleaching, while the adhesive binds the powder particles together and to the filament surface.
3Manufacturing precision
If white coated powder is painted on the internal surface of the glass shell, then the glass shell achieves white coating, but the photoelectric parameters become unstable
Solution Approach 1:
The patent applies local quality by concentrating the white coated layer specifically on the filament surface where light is generated. This localized coating approach ensures that the photoelectric parameters are stabilized at the source of light emission, rather than relying on a diffuse coating on the glass shell interior, resulting in more consistent and controllable photoelectric performance.
Solution Approach 2:
The composite coating layer of white powder and adhesive provides stable photoelectric parameters by creating a uniform, adherent layer on the filament. This composite structure ensures consistent light reflection and diffusion properties, leading to stable and repeatable photoelectric performance across production batches.
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 simplified process reduces production costs and improves the stability of the white coated layer, ensuring manageable color bleaching and photoelectric parameters, enhancing the filament's performance and reducing client usage costs.
Implementation Method 1
painting glue doped with white coated powder to the surface of the filament body to form a white coated layer on the surface of package layer
Implementation Method 2
Drying after painting, the drying condition for the first is 80° C.-300° C./0.1 h-1.5 h, and then turn to a long bake for 100° C.-300° C./2 h-8 h
Data Source
AI summary
The present invention provides a white coated LED filament and its production process and LED bulb, optimizing the white coated powder from being painted originally on internal surface of the glass shell to be painted on the surface of the filament, thus forms a coated white layer on the surface of the filament, and bonds whit the filaments for one-time molding, which simplifies the existing internal powder painting process of the glass shells, and reduces the cost of the finished products in terms of the usage and production of the clients, and also greatly improving the stability of the white coated filament bulbs, so that the color bleaching and its photoelectric parameters are in a manageable state, therefore the production process is become simply, the cost is lower, and improve the clients' usage scope, reduce the clients' usage cost, and can satisfy the existing market client's requirements for the product of the filaments bulbs with white coated.