LED Manufacturing via Conductor Wire Retention
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Solution Overview
Problem
Light-emitting devices using LEDs are currently expensive, hindering their widespread adoption compared to conventional lighting options like incandescent bulbs and fluorescent lamps.
Innovation Solution
A method of manufacturing light-emitting devices involves retaining a conductor wire with strategically set mounting portions for LED placement, intersecting or winding it with rod members to optimize spacing, and sealing the LEDs with a translucent sealing member to reduce costs and improve efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manufacturing methods are used for LED light-emitting devices, then production cost is high, but productivity and work efficiency remain limited
Solution Approach 1:
The conductor wire is retained in a specific configuration before LED mounting, with mounting portions positioned at predetermined intervals. This preliminary arrangement of the conductor wire and mounting portions enables efficient automated mounting processes, reducing both production cost and improving productivity by preparing the structure in advance for mass production
Solution Approach 2:
The patent replaces traditional mechanical assembly methods with a retained conductor wire structure that allows for more efficient mounting. The conductor wire serves as both structural support and electrical connection, eliminating the need for separate mounting hardware and reducing manufacturing complexity and cost while enabling higher productivity
2Illumination intensity
If the straight-line distance between adjacent mounting portions is reduced, then more LEDs can be mounted in a given space improving brightness, but the distance along the conductor wire between mounting portions increases requiring longer conductor wire
Solution Approach 1:
The conductor wire is configured to extend in multiple directions rather than a single linear path, creating a two-dimensional or three-dimensional mounting pattern. This allows mounting portions to be positioned closer together in straight-line distance (increasing LED density and brightness) while the conductor wire follows an optimized path that minimizes total length by utilizing spatial dimensions effectively
Data Source
AI summary
A method for manufacturing a light-emitting device comprises retaining a conductor wire so that a straight-line distance between adjacent mounting portions while the conductor is retained is less than a distance along the conductor wire between the adjacent mounting portions; mounting a plurality of light emitting diodes to respective ones of the mounting portions on the retained conductor wire; and after the mounting step, sealing the plurality of light-emitting diodes mounted on the conductor wire.