LED Filament Metal Bracket Design for Deformation Resistance
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Solution Overview
Problem
Conventional LED filaments are prone to destruction due to slight deformation, leading to line rupture and breakdown of LED chips, which can cause the entire filament to fail.
Innovation Solution
The LED filament design includes a metal first and second bracket with a die bonding section and connection region, where the cross-sectional area of the die bonding region is larger than the connection region, and LED chips are securely fixed in the die bonding region, allowing for parallel connection of LED chips, even if some chips are destroyed or wires break, preventing complete filament destruction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If LED chips are fixed on a conventional LED filament, then the filament can emit light, but the filament is prone to destruction due to slight deformation causing line rupture and chip failure
Solution Approach 1:
The LED filament is divided into multiple independent LED chip units that can be separately mounted on the support wire. Each LED chip is individually secured, allowing the filament to segment and absorb deformation forces without causing complete line rupture, thereby improving reliability while maintaining light emission functionality
Solution Approach 2:
A flexible coating layer is applied to the support wire to provide cushioning and deformation absorption. This flexible film structure allows the filament to bend and deform without breaking the LED chips or causing line rupture, resolving the contradiction between maintaining light emission and improving resistance to deformation
2Reliability
If LED chips are connected in series to form a complete circuit, then the filament functions properly, but destruction of any single chip or wire breaks the entire circuit causing complete failure
Solution Approach 1:
The LED filament circuit is segmented into multiple independent parallel branches, each containing LED chips connected in series. This segmentation allows the circuit to maintain functionality even if one branch fails, as other branches continue to operate, thereby improving reliability without significantly increasing overall circuit complexity
Solution Approach 2:
The circuit configuration changes from a single series connection to a parallel connection of multiple series branches. This parameter change in circuit topology provides redundancy, ensuring that the filament remains functional even when individual chips or wires are destroyed, while maintaining manageable circuit complexity
Data Source
AI summary
A LED filament includes LED chips, a first bracket and a second bracket. The LED chips are secured on the first bracket and/or the second bracket. The first bracket and the second bracket are made out of metal. Two ends of each of the LED chips are electrically connected with the first bracket and the second bracket, or the plurality of LED chips are divided into groups of serially connected LED chips. Two ends of each of the groups of serially connected LED chips are electrically connected with the first bracket and the second bracket.