Flexible LED Filament Alignment Member for Light Distribution
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Solution Overview
Problem
Flexible LED filaments typically emit most of their light from a single side, making it difficult to achieve uniform light distribution and emulate the look of incandescent bulbs, which is a drawback in retrofit lighting solutions.
Innovation Solution
A flexible LED filament with an elongated, rounded core and a protruding alignment member that extends at an angle, allowing for improved positioning, alignment, and directionality, facilitating better light distribution and handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flexible LED filaments are designed with LEDs arranged on one side of the carrier, then the structure is simplified and manufacturing is easier, but light distribution becomes uneven with most light emitted from a single side
Solution Approach 1:
The patent introduces an alignment member that protrudes from the filament core at an angle (e.g., 45 degrees) relative to the longitudinal axis, creating an asymmetric structure. This asymmetric design enables the filament to be positioned at specific orientations within the lamp, allowing the single-sided LED arrangement to achieve uniform light distribution by directing the light-emitting side toward the lamp envelope in multiple directions through proper angular positioning.
2Ease of manufacture
If the LED filament has a circular core, then the structure is simple and manufacturing is easy, but positioning and alignment within the lamp becomes difficult
Solution Approach 1:
The alignment member protruding at an angle from the otherwise circular filament core introduces asymmetry that provides a reference feature for positioning. This asymmetric element allows handling means to grasp and orient the filament at specific angles, enabling precise alignment of the LED array with the lamp envelope while maintaining the simplicity of the circular core structure for manufacturing.
Solution Approach 2:
The alignment member acts as an intermediary element between the circular filament core and the handling/positioning system. It provides a interface for gripping tools to engage with the filament, translating the simple circular geometry into a form that can be easily positioned and aligned within the lamp assembly without requiring complex structural modifications to the core itself.
3Ease of operation
If alignment members are added to the LED filament, then positioning and light distribution improve, but the device complexity increases
Solution Approach 1:
The alignment member is designed as a discrete, separate component that protrudes from the filament core rather than being integrated into the core structure itself. This segmentation allows the alignment function to be added independently to the simple circular core, providing positioning capability without requiring complex redesign of the entire filament structure. The modular nature minimizes the increase in overall device complexity.
Data Source
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AI summary
The present disclosure relates to a light-emitting diode, LED, filament (100) including a filament core. The filament core comprises a flexible elongated carrier (102) having a first side, a plurality of LEDs (104) arranged on the first side, and an encapsulant (106) embedding at least said plurality of LEDs and at least a portion of the carrier. At least one alignment member (108) protrudes from the filament core at an angle from an elongation of the filament core.