LED Bulb Power Connection Unit for Stable Electrical Contact

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Solution Overview

Problem

Traditional LED bulbs face issues with wire breakage, loose solder joints, and unstable illumination due to high temperatures, leading to potential short circuits and electrical shocks, primarily because of the small internal space and conventional wire connections.

Innovation Solution

The LED bulb employs a power connection unit with electrical terminals and power pins instead of wires, ensuring a secure and space-efficient electrical connection between the bulb head, power PCBA, and illumination module, maintaining stability even under high temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If wire connections are used for electrical connection between bulb head and power PCBA, then the connection can be easily implemented, but wire breakage and loose solder joints occur due to high temperature

Engineering Contradiction:

Improveease of connection implementationVSAvoidelectrical connection stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent merges the electrical connection function into the structural components themselves. The power connection unit integrates contact pieces that directly contact electrical terminals, eliminating the need for separate wire connections. This integration ensures stable electrical connection under high temperature while maintaining ease of assembly through direct structural contact.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces the mechanical wire connection system with a direct structural contact system. Instead of using wires that require soldering and are prone to breakage, the design uses rigid contact pieces that are structurally integrated into the housing and power PCBA, providing more reliable electrical connection that resists high temperature effects.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If wires are used for electrical connection, then the connection can be established, but the internal space of LED bulb is wasted

Engineering Contradiction:

Improveconnection implementationVSAvoidinternal space utilization

Core Design Contradiction:

Ease of manufactureVSVolume of stationary object

Solution Approach 1:

The electrical connection components are merged with the structural components of the bulb. The contact pieces are integrated into the housing structure, and the electrical terminals are formed as part of the housing features. This eliminates the need for separate wire elements and optimizes the use of internal space while maintaining connection functionality.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If conventional wire connections are used, then assembly is simple, but short circuit and electric shock risks increase due to wire loosening

Engineering Contradiction:

Improveassembly simplicityVSAvoidshort circuit and electric shock risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The electrical connection system is merged with the structural housing and power PCBA components. This integration eliminates loose wire ends that could cause short circuits or electric shocks. The contact pieces are firmly positioned within the housing structure, providing safe and secure electrical connections that prevent harmful effects.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If wire connections are used, then electrical connection can be achieved, but wire breakage occurs under high temperature conditions

Engineering Contradiction:

Improveelectrical connection capabilityVSAvoidresistance to high temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent replaces the temperature-sensitive wire connection system with a structurally integrated contact system. The contact pieces and electrical terminals are made of materials and designed in a way that maintains structural integrity and electrical conductivity under high temperature conditions, eliminating wire breakage issues.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS8963410B2LED bulb

Publication Date: 2015.02.24 WELL SHIN TECH

AI summary

A LED bulb includes a bulb head, a power PCBA of which a bottom is equipped with power pins, a LED PCB mounted to a top of the power PCBA and electrically connecting with the power PCBA, and a cover covered on the LED PCB. The bulb head includes a housing, electrical terminals disposed in the housing and including an anode terminal and a cathode terminal, and a power connection unit mounted to a bottom of the housing and including a bulb base and an anode element. One end of the anode terminal is electrically connected with a top end of the anode element. One end of the cathode terminal projects outside the housing to be electrically connected with the bulb base. The power PCBA is mounted on the housing. The power pins are electrically connected with another two ends of the anode terminal and the cathode terminal.