LED Light Bulb Driver Substrate Integration
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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, requiring intricate assembly and increasing 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 guiding the circuit board's position, and a radiator for heat dissipation, where the driver circuit board is connected to the lamp cap electrodes without wires, simplifying assembly and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical wires are used to connect the driver source to the LED light source, then reliable 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 soldering or conductive bonding on the substrate.
Solution Approach 2:
The patent extracts the electrical connection function from the mechanical assembly process by integrating the driver circuit directly onto the aluminum substrate that also carries the LED modules. This extraction eliminates the intermediate electrical wires and reduces assembly complexity while preserving electrical reliability.
2Reliability
If electrical wires are used to connect the driver source to the LED light source, then electrical connection is established, but manufacturing cost increases
Solution Approach 1:
The driver source is merged with the LED aluminum substrate into a single integrated unit. This consolidation eliminates the need for separate electrical wires, reducing material costs and manufacturing complexity while maintaining reliable electrical connection through the substrate's conductive pathways.
Solution Approach 2:
The LED aluminum substrate serves multiple functions: it acts as the mechanical support structure for mounting LED modules, provides thermal management through heat dissipation, and serves as the electrical connection medium between the driver source and LED light source. This multi-functionality eliminates the need for separate electrical wires and reduces manufacturing cost.
3Volume of moving object
If the driver source is contained in the sleeve tube in the center of the radiator, then compact structure is achieved, but electrical wire routing becomes complicated
Solution Approach 1:
The driver source is merged directly with the LED aluminum substrate, eliminating the need for a separate sleeve tube structure. This integration maintains compactness while simplifying wire routing, as the electrical connections are established directly on the substrate plane rather than requiring wires to pass through the center of the radiator.
4Reliability
If electrical wires pass through the center of the radiator to connect the driver source, then electrical connection is achieved, but assembly process becomes complicated
Solution Approach 1:
The driver source and LED aluminum substrate are merged into a single integrated unit, eliminating the need for electrical wires to pass through the radiator center. This integration dramatically simplifies the assembly process, allowing the entire driver-LED assembly to be mounted as one unit, thereby improving productivity without compromising electrical connection reliability.
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 by eliminating the need for electrical wires and improving the structural integrity of the light bulb.
Implementation Method 1
The substrate may be implemented as a plate that has aluminum material for better heat dissipation
Implementation Method 2
The radiator, which may be used for heat dissipation
Implementation Method 3
The radiator, which may be used for heat dissipation, has a top plate and a side wall
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.