LED Filament Lamp Structure to Prevent Conductive Filament Bending
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Solution Overview
Problem
LED filaments in existing LED bulbs are prone to bending or deformation due to exposure of conductive filaments, affecting normal operation and stability during transportation.
Innovation Solution
An improved LED lamp design featuring a display positioning block that covers the middle and upper ends of conductive filaments, along with a positioning seat and decorative modeling part, ensuring stability and preventing deformation, while allowing for easy replacement and customization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the conductive filaments are left exposed between the injection-molded rubber plug and the LED filament, then the manufacturing process is simpler, but the conductive filaments are prone to bending or deformation during transportation
Solution Approach 1:
The display positioning block is pre-formed with cavities and protrusions that correspond to the conductive filaments' positions. During assembly, the conductive filaments are inserted into these pre-positioned cavities, which preliminarily constrain their positions and prevent bending or deformation during transportation and installation.
Solution Approach 2:
The display positioning block serves as an intermediary component between the injection-molded rubber plug and the LED filament. It provides a structured interface with specific cavities and protrusions that mediate the connection, ensuring the conductive filaments are properly positioned and protected without requiring complex modification of the existing components.
2Reliability
If the display positioning block covers the middle and upper ends of the conductive filaments, then the anti-deformation performance is improved, but the device structure becomes more complex
Solution Approach 1:
The display positioning block performs multiple functions simultaneously: it positions the conductive filaments, protects them from deformation, provides structural support, and serves as a mounting interface for the LED filament. By consolidating these functions into a single component, the overall device complexity is minimized while achieving the desired protection.
Solution Approach 2:
The design merges the positioning, protection, and support functions into the display positioning block, which is integrated with the existing lamp structure. The block combines rigid and flexible elements to provide both structural support and deformation protection, reducing the need for separate components.
3Reliability
If the conductive filaments are fully packaged by the display positioning block, then the stability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The display positioning block is segmented into distinct functional zones: cavities for receiving conductive filaments, protrusions for positioning, and regions for LED filament mounting. Each segment is designed with specific tolerances, allowing modular manufacturing and assembly while maintaining overall positioning precision.
Solution Approach 2:
Different regions of the display positioning block have different structural characteristics optimized for their specific functions. The cavities have precise dimensions for filament reception, while the protrusions have matching geometries for positioning. This local optimization of quality reduces the overall manufacturing precision requirements compared to a uniformly precise design.
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
The design enhances the stability of conductive filaments, prevents deformation and bending, facilitates transportation, and allows for easy replacement of components, while also enabling decorative customization and reducing replacement costs.
Implementation Method 1
the middle and upper ends of the two conductive filaments and the lower ends of the substrate and the two conductive parts are covered by the injection-molded display positioning block
Implementation Method 2
the lower end of the display positioning block is clamped in the positioning hole in a matchable way to position the LED filament
Data Source
AI summary
The invention discloses an improved novel LED lamp, which comprises a lampshade, an LED filament, a lamp cap and a positioning seat; the LED filament comprises a substrate, an LED light source, a packaging layer, two conductive parts, two conductive filaments and a display positioning block; the middle and upper ends of the two conductive filaments and the lower ends of the substrate and the two conductive parts are covered by the injection-molded display positioning block. The display positioning block of the invention is used to cover the middle and upper ends of the conductive filaments to prevent the conductive filaments from being deformed and bent.