LED Light Bulb Stemless Power Wire Support Structure
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Solution Overview
Problem
Conventional LED light bulb fabrication methods are complex and costly due to the need for a stem to support the LED filament, limiting the bulb's size and efficiency.
Innovation Solution
The use of a power wire support set, comprising dumet wires and fixed blocks, replaces the stem, allowing the LED filament to be directly soldered to the wires and enclosed within a glass envelope, eliminating the need for internal space and simplifying the fabrication process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a stem is provided to support the LED filament, then the LED filament can be supported and positioned, but the fabrication method becomes complicated and the bulb length increases
Solution Approach 1:
The patent combines the support function and electrical connection function into a single integrated structure. The copper cap both supports the LED filament and provides electrical connection, eliminating the need for a separate stem component. This merging of functions simplifies the overall structure and fabrication process while maintaining the necessary support and positioning capabilities.
Solution Approach 2:
The copper cap serves multiple functions simultaneously: it acts as a support structure for the LED filament, provides electrical connection through soldering, and serves as a sealing element when combined with the glass envelope. This multi-functionality eliminates the need for separate dedicated support components, reducing structural complexity.
2Stability of the object's composition
If a stem is provided to support the LED filament, then the LED filament can be supported, but internal space is required and bulb length cannot be reduced
Solution Approach 1:
The support function is merged with the electrical connection component (copper cap), eliminating the need for a separate stem that would occupy internal space. The LED filament is directly supported by the copper cap structure, which also provides electrical connection, thereby reducing the overall bulb length.
Solution Approach 2:
The traditional stem structure is extracted/removed from the design. Instead of using a separate stem component, the support function is integrated into the copper cap assembly, eliminating the space-consuming stem structure and enabling more compact bulb dimensions.
3Stability of the object's composition
If a stem is provided to support the LED filament, then the LED filament can be positioned, but fabrication costs increase
Solution Approach 1:
The positioning and support functions are merged with the electrical connection component. The copper cap structure provides both mechanical support for positioning the LED filament and electrical connection capabilities, eliminating the need for separate stem components and reducing overall fabrication costs.
Solution Approach 2:
The copper cap serves as a multi-functional component that simultaneously provides structural support for positioning, electrical connection through soldering, and sealing integration with the glass envelope. This universality reduces the total component count and fabrication complexity, leading to cost reduction.
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 approach reduces fabrication costs, allows for a significant reduction in bulb length, and enables the production of small-size LED light bulbs by eliminating the need for stem accommodation, making the process more efficient and cost-effective.
Implementation Method 1
a first power wire, a second power wire and at least one fixed block, wherein the fixed block fixes the first and second power wires to make them form a power wire supporting structure
Implementation Method 2
An LED filament having two ends respectively soldered to a first end of the first power wire and a first end of the second power wire
Data Source
Figure 1
Figure 2-1~2-2
Figure 2-3~2-4
AI summary
An LED light bulb (1) and a fabrication method thereof are provided. A plurality of power wires (111,112) for supplying electricity to an LED filament (12) are fixed to form a power wire supporting structure for supporting and fixing the LED filament (12) in position, without using a stem of a conventional LED light bulb, thereby simplifying fabrication processes of the LED light bulb (1) and reducing fabrication costs thereof. Moreover, the LED light bulb does not require an internal space for accommodating the stem, and thus its length can be effectively reduced to ideally become a small-size light bulb.