LED Bulb Driver Nesting for Thermal Protection
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Solution Overview
Problem
The existing LED lighting bulbs face challenges in incorporating a lighting driver without increasing the bulb's size or damaging it during high-temperature sealing processes, as the driver must be positioned within the end cap, which affects aesthetics and internal space utilization.
Innovation Solution
The LED lighting bulb design allows the lighting driver to be positioned within the bulb envelope, protected by slideable wires and tubes, enabling it to be safely seated during high-temperature sintering and allowing for a more compact and aesthetically pleasing form factor by utilizing the internal volume of the bulb.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lighting driver is positioned within the end cap, then the bulb maintains a traditional appearance and compact size, but the lighting driver is exposed to high temperature sintering damage during assembly
Solution Approach 1:
The lighting driver is pre-positioned inside the envelope before the sintering process occurs. The envelope is inserted into the end cap with the driver already in place, ensuring the driver is protected from thermal damage before any high-temperature processing occurs.
Solution Approach 2:
The lighting driver is nested inside the envelope, which itself is nested within the end cap structure. This nested arrangement allows the driver to be positioned within the bulb while being protected by the envelope during the sintering process, resolving the contradiction between compact positioning and thermal protection.
2Volume of stationary object
If the lighting driver is positioned within the end cap, then the bulb structure is compact, but the internal volume of the envelope is underutilized
Solution Approach 1:
Instead of placing the lighting driver in the end cap (traditional approach), the invention inverts the arrangement by positioning the driver inside the envelope. This inversion maximizes the use of the envelope's internal volume while maintaining a simple overall bulb structure.
3Shape
If the end cap is enlarged to accommodate the lighting driver, then the driver can be positioned outside the envelope, but the bulb's aesthetic appearance and compact size are compromised
Solution Approach 1:
The lighting driver is nested within the envelope, which is itself nested within the end cap. This nested arrangement allows the driver to be positioned inside the bulb without requiring an enlarged end cap, thereby maintaining the bulb's aesthetic appearance and compact size while still accommodating the driver.
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 solution protects the lighting driver from thermal damage during assembly, maintains a traditional incandescent lamp appearance, and allows for flexible positioning of the light source, ensuring robust electrical connections and uncluttered internal volume.
Implementation Method 1
the stem portion being hermetically connected to an opening of the envelope, with the lighting driver remote from the stem portion and within the envelope
Data Source
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AI summary
A LED lighting bulb (10) has a lighting driver (28) which is located within the bulb envelope (12). During assembly, the lighting driver (28) may be positioned away from an opening (14) of the envelope (12) so that high temperature sealing of a stem portion (22) of the end cap (16) to the envelope opening (12) can take place. The lighting driver (28) can then be pulled into position against the stem portion (22), and assembly of the end cap (16) can then be completed.