LED Bulb with Integrated Driving Module for Automated Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional LED bulbs are challenging to manufacture using industrial automated production due to a lack of a fixing structure between the LED driving module and the bulb body, leading to high production costs and low yield rates, as the connection requires manual soldering and is prone to errors.
Innovation Solution
The LED bulb features a hollow spherical bulb body made of transparent material with an integrally fixed lamp pole, a modular LED driving module with extended pins for connection to the lamp holder, and a conductor frame structure including a resistor, capacitor, and bridge rectifier, allowing for simplified assembly and automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the LED driving module is installed at the bulb and lamp cap positions, then the LED bulb can be connected to traditional lamp holders, but the bulb structure becomes complex and cannot be entered into automated production lines
Solution Approach 1:
The invention divides the LED bulb into separate functional modules: the bulb body containing light-emitting components, and a separate LED driving module with connection terminals. This segmentation allows the bulb body to maintain a simple, automated-production-friendly structure while the driving module handles the adaptation function for traditional lamp holders through its lamp cap simulation structure.
2Reliability
If the LED driving module is connected to the lamp cap electrodes and light emitting strip electrodes, then electrical connection is achieved, but the installation becomes troublesome and requires manual soldering
Solution Approach 1:
The LED driving module incorporates a built-in lamp cap simulation structure with connection terminals that directly interface with the lamp holder electrodes. This self-contained design eliminates the need for external wiring and manual soldering operations, as the module self-establishes electrical connections when installed into the lamp holder.
3Ease of manufacture
If the LED driving module and bulb body are fixed by glue without a fixing structure, then assembly is simple, but the LED driving module can be easily pulled out during lead pulling causing poor yield rate
Solution Approach 1:
The invention merges the lamp cap simulation structure with the LED driving module into a single integrated component. The lamp cap simulation structure serves dual functions: providing mechanical support and fixation for the driving module, and enabling electrical connection through its connection terminals. This integration eliminates the need for separate fixing structures while ensuring stable assembly.
4Strength
If the lead is clamped between glass in conventional LED bulbs, then structural support is provided, but pulling the lead out from glass increases difficulty of automation
Solution Approach 1:
The invention extracts the lead routing function from the glass bulb body and relocates it to the LED driving module. The connection terminals on the driving module provide external connection points that bypass the need to pull leads through the glass, eliminating the automated manufacturing difficulty associated with lead extraction from glass while maintaining electrical connection integrity.
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 manufacturing process, reduces production costs, and enables high-yield automatic mass production by providing a stable and efficient electrical connection, enhancing the product's yield rate and promoting widespread use.
Implementation Method 1
an LED chip packaged in the LED driving module for driving an LED chip in the light strip
Data Source
AI summary
An LED bulb applicable for industrial automated production includes a bulb body, a lamp holder, an LED driving module, a lamp pole, and a light strip. The bulb body is coupled to the lamp holder. The bulb body is made of a transparent material and in a hollow spherical shape. The lamp pole is installed and integrally fixed into the bulb body. The light strips are installed on the lamp pole and formed into a lamp module, and the light strips are connected in series or in parallel with each other. The LED driving module has a hole at the center sheathed on the lamp pole, so that the LED driving module is disposed in the bulb body. The invention has a simple structure and builds in the LED driving module to simplify the manufacturing procedure and lower the level of difficulty of the manufacture.