Self-supporting LED filament light engine with arcular base contacts
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Solution Overview
Problem
Existing light engines for LED retrofit lamps require auxiliary arbor and wire support structures, which complicates their design and construction, especially for automated manufacturing processes within conventional bulb assembly dimensions.
Innovation Solution
A light engine design employing filament LEDs with an anode and cathode supporting base contacts of arcular geometry, where the LEDs are connected at a common apex interface, eliminating the need for auxiliary support structures by utilizing the frame structure for electrical connections, allowing for automated construction and integration into lamp fixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If auxiliary arbor and wire support structures are used in LED light engines, then structural support and electrical connections are provided, but device complexity increases and automated construction becomes difficult
Solution Approach 1:
The patent combines the structural support function and electrical connection function into a single integrated frame structure. The frame structure serves dual purposes: providing mechanical support for the LED filaments and establishing electrical connections between them, thereby eliminating the need for separate auxiliary support structures and wires, and reducing overall device complexity while enabling automated construction
Solution Approach 2:
The frame structure is designed to perform multiple functions simultaneously: it acts as a mechanical support structure, an electrical connection network, and a positioning framework for automated assembly. This multi-functionality reduces the number of components needed and simplifies the overall light engine design
2Adaptability or versatility
If conventional bulb assembly dimensions are used, then compatibility with existing fixtures is maintained, but space constraints complicate light engine design
Solution Approach 1:
The light engine is designed as a modular assembly with segmented components that can be efficiently packed within conventional bulb dimensions. The frame structure is divided into segments that support individual LED filaments, allowing for compact arrangement while maintaining standard bulb外形 for fixture compatibility
3Productivity
If automated construction is implemented, then productivity increases, but precise positioning and alignment requirements increase manufacturing precision demands
Solution Approach 1:
The frame structure is pre-configured with integrated positioning features and electrical connection points before LED filament assembly. This preliminary preparation enables automated construction equipment to easily locate and assemble components without requiring high-precision real-time adjustments, thereby increasing productivity while managing manufacturing precision requirements
Data Source
AI summary
A light emitting diode (LED) light engine that includes an anode supporting base contact having a first arcular geometry; a cathode supporting base contact having a second arcular geometry; and a plurality of light emitting diode (LED) filament structures connected in series, the plurality of light emitting diode (LED) filament structures all connected at a common apex interface, wherein at least a first of the plurality of light emitting diode (LED) filament structures has an anode contact in electrical communication with the anode supporting base contact, and at least a second of the plurality of light emitting diode (LED) filament structures of has a cathode contact in electrical communication with the cathode supporting base contact.