LED Lighting Device Mechanical Fastening Stem
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of LED lighting devices is cumbersome due to complex structures for fastening the light generating unit to the core column, making it difficult to leverage existing manufacturing equipment designed for incandescent lighting devices.
Innovation Solution
A lighting device with a mechanical fastening part featuring protrusions that mate with holes in the light generating unit, allowing for a simpler and more rigid connection to a stem, facilitating the use of existing manufacturing equipment and enabling the light generating unit to be supported within an envelope, similar to traditional incandescent designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a complex fastening structure (steel needle and chuck) is used to connect the light generating unit to the core column, then the connection strength is improved, but the device complexity increases and manufacturing becomes cumbersome
Solution Approach 1:
The fastening structure is segmented into distinct functional elements: a stem with an integrated fastening feature (protrusion or thread) and a light generating unit with a corresponding mating feature (hole or threaded opening). This segmentation allows each component to be manufactured independently using simple processes while achieving a strong combined connection.
Solution Approach 2:
Instead of using a complex multi-part fastening mechanism, the patent inverts the approach by using a simple insertional or threaded connection where the light generating unit is inserted into or screwed onto the stem. This reverse simplification achieves adequate connection strength without complexity.
2Device complexity
If a simple fastening structure is used to connect the light generating unit to the stem, then the device complexity is reduced and manufacturing is facilitated, but the connection strength and ability to withstand high g-forces deteriorates
Solution Approach 1:
The essential fastening function is extracted from complex mechanical assemblies and embodied in a single integrated stem component with a protrusion or thread. This extraction eliminates unnecessary complexity while maintaining the core function of providing a strong connection point for the light generating unit.
Solution Approach 2:
The stem's fastening feature (protrusion or thread) is designed to self-align and self-secure with the light generating unit's mating feature during insertion or assembly. This self-service mechanism eliminates the need for additional fastening components or complex assembly procedures while ensuring adequate connection strength.
3Productivity
If existing manufacturing equipment for incandescent lighting devices is utilized, then productivity is improved and manufacturing cost is reduced, but the ability to manufacture modern LED lighting devices with different structural requirements deteriorates
Solution Approach 1:
The stem is designed as a universal component that can be manufactured using traditional incandescent lighting equipment while accommodating modern LED light generating units. The standardized stem design with integrated fastening features allows existing manufacturing lines to produce both traditional and LED lighting devices without modification, achieving multi-functionality.
Solution Approach 2:
The patent maintains homogeneity in the stem design and manufacturing process, allowing the same equipment and procedures used for traditional incandescent bulbs to be applied to LED lighting devices. This homogeneous approach ensures consistent manufacturing quality and process compatibility across different lighting technologies.
Data Source
AI summary
A lighting device (1) and a method of manufacturing a lighting device is provided. The lighting device comprises an envelope (100), a light generating unit (120), a stem (130) arranged to support the light generating unit inside the envelope, and a mechanical fastening part (110) arranged to fasten the light generating unit at the stem. The mechanical fastening part comprises at least one protrusion (115) and the light generating unit comprises at least one hole (126) adapted to mate with the at least one protrusion so as to fasten the light generating unit to the mechanical fastening part.