LED Light Bulb Driver Integration via Aluminum Substrate
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Solution Overview
Problem
The existing LED lamp manufacturing process is complicated and costly due to the need for electrical wires to connect the driver source to the LED light source, which requires complex assembly and increases production expenses.
Innovation Solution
A light bulb apparatus design featuring LED modules mounted on an aluminum substrate with a driver circuit board, a plastic piece with a guiding groove, and a radiator for heat dissipation, where the driver circuit board is inserted into the plastic piece to ensure correct positioning and eliminate the need for electrical wires by using a lamp cap with insulated electrodes for electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical wires are used to connect the driver source to the LED light source, then electrical connection is achieved, but the assembly process becomes complicated and manufacturing cost increases
Solution Approach 1:
The patent combines the driver source and LED light source into a single integrated structure where the driver is mounted directly on the LED aluminum substrate. This eliminates the need for separate electrical wire connections and complex assembly processes, while maintaining reliable electrical connection through direct mounting and integrated circuit board design
Solution Approach 2:
The LED aluminum substrate serves multiple functions: it acts as both the mounting base for the driver source and the heat dissipation radiator, while also providing the electrical connection path to the LED light source. This multi-functionality reduces the need for separate components and simplifies the overall assembly
2Reliability
If electrical wires are used to connect the driver source to the LED light source, then electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The patent merges the driver source mounting and electrical connection functions into the LED aluminum substrate itself, eliminating the need for separate electrical wires. This integration reduces component count, assembly steps, and manufacturing cost while ensuring reliable electrical connection through the integrated circuit board design
Solution Approach 2:
The patent extracts the electrical wire connection function entirely from the design by implementing direct electrical connection through the integrated driver mounting on the LED aluminum substrate. This removal of unnecessary components directly reduces manufacturing cost while maintaining electrical connection reliability
3Reliability
If the driver source is contained in the sleeve tube in the center of the radiator, then electrical connection is achieved, but the assembly process becomes complicated
Solution Approach 1:
The patent combines the driver source containment and electrical connection functions into the LED aluminum substrate structure. The driver is mounted directly on the substrate which serves as both the containment structure and the electrical connection path, eliminating the need for separate sleeve tubes and wire routing through the radiator center
Solution Approach 2:
The patent segments the driver source and LED light source into separate functional modules mounted on the same LED aluminum substrate. This segmentation allows for independent assembly and mounting of each module while maintaining simple electrical connection through the substrate's circuit board, avoiding the complexity of routing wires through the radiator center
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 design simplifies the assembly process, reduces manufacturing costs, and enhances heat dissipation efficiency while maintaining the structural integrity and aesthetic appeal of the LED light bulb.
Implementation Method 1
The radiator, which may be used for heat dissipation, has a top plate and a side wall
Implementation Method 2
The substrate may be implemented as a plate that has aluminum material for better heat dissipation
Data Source
AI summary
A light bulb apparatus has a plurality of LED modules, a substrate, a driver circuit board, a plastic piece, a radiator and a lamp cap. The substrate has aluminum material for mounting the plurality of LED modules, a first connection end and a second connection end. The first connection end and the second connection end are electrically connected to the plurality of LED modules. The plastic piece with a guiding groove is used for inserting the driver circuit board. The radiator has a top plate and a side wall. The substrate is fixed on the top plate, and the side wall are connected to the plastic piece.