Integrated LED Light Bulb Socket Base Alignment
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Solution Overview
Problem
Existing LED SMD light bulb systems face issues with connection reliability, alignment of metal contacts, and vibration resistance, leading to inefficient and unstable light emission, particularly in vehicular applications.
Innovation Solution
An integrated LED light bulb system that combines a socket base with a support circuit board and multiple circuit boards, featuring metal contactors and resistors to ensure proper alignment and power distribution, reducing connection issues and enhancing stability against vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If separate LED bulb and base design is used, then ease of replacement is improved, but connection reliability and alignment precision deteriorate
Solution Approach 1:
The patent merges the LED bulb and base into a single integrated unit, eliminating the interface between separate components. The circuit board serves as both the mounting platform for LEDs and the electrical connection element, ensuring reliable electrical contact while maintaining ease of replacement as a complete unit.
Solution Approach 2:
The integrated unit is segmented into functional modules: the base portion with contactors, the circuit board with mounted LEDs, and the housing. This modular integration allows the entire assembly to be replaced as one unit while internal connections are pre-established, combining replacement ease with connection reliability.
2Device complexity
If separate LED bulb and base design is used, then device complexity is reduced, but manufacturing precision and alignment accuracy deteriorate
Solution Approach 1:
By combining the base and bulb into one integrated unit, the patent eliminates alignment issues between separate components. The circuit board is pre-mounted with precise alignment to the contactors and LED positions, ensuring manufacturing precision without increasing overall device complexity.
3Reliability
If integrated one-piece design is used, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The integration merges multiple functions into unified components: the circuit board serves as both structural support and electrical conductor, the housing provides both mechanical protection and mounting structure. This functional integration improves connection reliability while the overall device complexity remains manageable due to the streamlined design.
4Stability of the object's composition
If integrated LED bulb system is used, then vibration resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The integrated design creates a rigid, unified structure that resists vibration better than separate components. The circuit board is firmly mounted within the housing with pre-positioned LEDs and contactors, eliminating relative movement between parts. While manufacturing requires precise integration, the overall process remains feasible using standard SMT and assembly techniques.
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 integrated design improves connection reliability, ensures proper alignment of metal contacts, and enhances stability, resulting in more efficient and robust LED light emission, reducing costs and simplifying replacement processes.
Implementation Method 1
Light bulbs, such as T-10 style light bulbs and LED's
Data Source
AI summary
An LED light bulb system that has a socket base and a contactor arranged in the socket base. The light bulb system also has a support circuit board secured to the socket base and a plurality of circuit boards connected to the support circuit board in a vertical direction. The light bulb also uses at least one resistor on each of the plurality of circuit boards to operate the LED.