Lamp Base Electrical Contact Design for LED Assembly
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Solution Overview
Problem
Existing lamps with light emitting semiconductor components are complex and costly to produce, requiring intricate electrical connections that complicate assembly and stability.
Innovation Solution
A lamp design featuring a base with external electrical connections and carrier-mounted light emitting semiconductor components connected via electrical contacting elements, which are either welded, soldered, or adhesively bonded, allowing for simple assembly and mechanical stability through spring force or deformation of base components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connections are used for mounting light emitting semiconductor components, then reliable electrical contact is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the electrical connection function with the mechanical mounting function by integrating electrical contacting elements directly into the base structure. The base serves dual purposes: providing mechanical support and establishing electrical contact, thereby reducing the number of separate components and simplifying the overall device complexity while maintaining reliable electrical contact.
Solution Approach 2:
The base is designed as a multi-functional component that simultaneously provides mechanical support, positioning, and electrical connection. The electrical connection parts are integrated into the base structure, allowing a single component to fulfill multiple functions that would traditionally require separate elements, thus reducing device complexity without compromising reliability.
2Reliability
If multiple separate electrical connections are used, then reliable electrical contact is achieved, but ease of manufacture decreases
Solution Approach 1:
The patent combines multiple electrical connection functions into integrated electrical connection parts that are formed as single pieces within the base. This merging of functions allows for simplified assembly processes, as fewer separate components need to be handled and connected during manufacturing, thereby improving ease of manufacture while maintaining reliable electrical contact.
Solution Approach 2:
The electrical connection parts are pre-formed and integrated into the base structure before the final assembly step. This preliminary action of creating ready-to-connect electrical pathways in the base simplifies the subsequent assembly process, allowing light emitting semiconductor components to be mounted with straightforward connection to pre-positioned electrical contacts.
3Reliability
If rigid electrical connections are used, then electrical stability is achieved, but mechanical stability and ease of assembly decrease
Solution Approach 1:
The patent introduces elastic elements into the electrical connection parts, transforming rigid connections into dynamic, flexible connections. These elastic elements allow the electrical connection parts to adapt to dimensional variations and mounting tolerances, providing both mechanical stability through flexibility and electrical stability through maintained contact pressure, while facilitating easier assembly.
Solution Approach 2:
The patent changes the physical parameters of the electrical connection parts by incorporating elastic properties. This parameter change from rigid to elastic allows the connection parts to accommodate dimensional variations and provide self-adjusting contact pressure, thereby improving mechanical stability and ease of assembly while maintaining reliable electrical contact.
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 design simplifies the assembly process, eliminates the need for additional electrical connections, and ensures a stable mechanical and electrical contact, making the lamp production more economical and efficient.
Implementation Method 1
Each electrical contacting element of the base is directly adjacent to one of the electrical connection parts of the base and connected to it in an electrically conducting manner
Implementation Method 2
one of the electrical contacting elements and/or one of the electrical connection parts is designed to be elastic, so that the contacting element and the connection part are pressed on to each other by means of a spring force
Implementation Method 3
at least one light emitting semiconductor component mounted on a carrier
Data Source
AI summary
A lamp with a base (1) and at least one light emitting semiconductor component (2) is disclosed. The base has at least two external electrical connections (11, 12) and at least two electrical connection parts (13, 14). The electrical connection parts are provided for electrically connecting the light emitting semiconductor component and are respectively connected to one of the external electrical connections in an electrically conducting manner. The light emitting semiconductor component is mounted on a carrier (3) and is electrically connected to at least two electrical contacting elements (31, 32), which are arranged and/or fixed on the carrier. Each of the electrical contacting elements is directly adjacent to one of the electrical connection parts and connected to it in an electrically conducting manner.