Lamp Base Contact Elements for Solder-Free LED Assembly
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Solution Overview
Problem
Existing lamp assembly methods require complex and costly soldering of long wires for electrical connections, leading to potential assembly errors and limited compatibility with different base types.
Innovation Solution
A lamp design featuring a base with integrated driver and contact elements that allow for secure, reliable electrical contact without the need for precise wire positioning, enabling easy assembly and compatibility with various base types through the use of contact elements that project into the bulb for secure power line insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If long flexible wires are used to connect the driver to the bulb, then electrical connection is achieved, but assembly complexity and production cost increase due to soldering requirements
Solution Approach 1:
The patent extracts the complex wire connection process by integrating the electrical contact function directly into the base structure through contact elements. This eliminates the need for separate flexible wires and soldering operations, reducing assembly complexity while maintaining reliable electrical connection between the driver and bulb.
Solution Approach 2:
The patent merges the electrical contact function with the base structure by integrating contact elements directly into the base. This combination eliminates separate wire components and soldering steps, simplifying the overall assembly process while ensuring reliable electrical connection.
2Reliability
If soldering is used to connect wires to the driver and bulb, then reliable electrical contact is achieved, but production time and manufacturing cost increase
Solution Approach 1:
The patent removes the soldering process entirely by using contact elements that establish electrical connection through simple insertion or contact. This extraction of the soldering step dramatically increases assembly speed and productivity while maintaining reliable electrical contact between components.
Solution Approach 2:
The contact elements are pre-integrated into the base structure during manufacturing, so that when the bulb is installed, electrical connection is immediately established without requiring on-site soldering. This preliminary integration of the contact function accelerates the final assembly process.
3Reliability
If precise wire positioning is required for electrical connection, then contact reliability improves, but manufacturing precision requirements and production cost increase
Solution Approach 1:
The patent extracts the positioning requirement by using contact elements with built-in alignment features or flexible contact surfaces. This eliminates the need for precise wire positioning during assembly, reducing manufacturing precision requirements while ensuring reliable electrical contact.
Solution Approach 2:
The patent changes the geometric parameters of the contact elements, such as their shape, flexibility, or positioning features, to provide self-alignment or tolerance compensation. This allows reliable electrical contact to be achieved without requiring high manufacturing precision in the assembly process.
4Volume of moving object
If the driver is located at an inaccessible point in the base, then compact design is achieved, but electrical connection becomes more difficult
Solution Approach 1:
The patent extracts the electrical connection function from the bulb and relocates it to the base through integrated contact elements. This allows the driver to be positioned at any location within the base, including inaccessible points, while maintaining ease of assembly through the standardized contact interface.
Solution Approach 2:
The contact elements are designed with universal functionality to accommodate different driver positions within the base. The standardized contact interface ensures that regardless of where the driver is located, electrical connection can be reliably established through the same assembly process.
Data Source
AI summary
A lamp includes a base, a light-permeable bulb containing at least one light source, and a driver for powering the light source. The driver is located within the base. The bulb has outwardly leading supply lines on the base side, and the driver has at least one contact element which projects in the direction of the bulb into which a free-standing section of the respective supply line is inserted to make contact. The technology is particularly applicable to lamps with LEDs as light sources, in particular for replacement of conventional lamps such as incandescent lamps.