LED Filament Light Support Bar Design
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Solution Overview
Problem
Current LED filament light designs using glass cores are prone to breakage during production and transportation, leading to low yield and increased production complexity due to the need for metal wires for electrical connections.
Innovation Solution
The design incorporates a support bar made of a rigid material, such as metal, to connect and support LED filament strips, eliminating the need for glass cores and simplifying the production process by directly welding electrodes for electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass core is used to support LED filament strips, then structural support is provided, but breakage occurs during production and transportation leading to low yield
Solution Approach 1:
The patent replaces the fragile glass core with a metal wire framework that can be easily manufactured and assembled. The metal wire structure serves as a durable support that eliminates the breakage issues of glass cores during production and transportation, thereby improving production yield while maintaining structural support functionality.
Solution Approach 2:
The patent employs a composite structure combining metal wires for mechanical support and glass only where absolutely necessary for electrical insulation or sealing. This composite approach retains the structural advantages of metal while minimizing glass usage, reducing breakage risk during handling and production.
2Reliability
If glass core is used to support LED filament strips, then structural support is provided, but additional metal wires must be poured in middle of top part increasing process steps
Solution Approach 1:
The patent extracts the metal wire support function from the glass core structure. Instead of embedding metal wires into a glass core, the design uses a standalone metal wire framework that provides structural support without requiring complex pouring and embedding processes. This simplifies the production process while maintaining the necessary structural integrity.
Solution Approach 2:
The patent segments the support function from the electrical connection function. The metal wire framework handles mechanical support independently, while separate electrical connection components handle conductivity. This segmentation eliminates the need for complex integrated glass-core-with-embedded-wires structures, reducing production process complexity.
3Reliability
If glass core with embedded metal wires is used, then electrical connections are achieved, but yield of stem and LED filament decreases
Solution Approach 1:
The patent uses simple, easily replaceable metal wire components for electrical connections instead of complex embedded wire structures in glass cores. These discrete metal wire components can be quickly assembled and replaced if needed, improving production yield by reducing the complexity and risk associated with embedding wires in glass during manufacturing.
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
This approach enhances the reliability and production efficiency of LED filament lights by reducing breakage and simplifying the manufacturing process, while maintaining the structural integrity and uniform illumination of the light source.
Implementation Method 1
the other end of the support bar is welded to the electrode of the two LED (Light Emitting Diode) filament strip
Implementation Method 2
the confined space is filled with heat dissipation gas
Data Source
AI summary
An LED filament light including a bulb, a support bar, at least two electrode wires and at least two LED filament strips. Each LED filament strip including a base, an LED chip is set on the base and an electrode is fixed at both ends of the base. One end of the electrode is electrically connected with an LED chip on the base, the other end of the electrode is electrically connected with an electrode of another LED filament or electrically connected to one end of the electrode wires so that the support bar is fixed to the bulb, and the other end is connected with at least one. As the support bar is set to replace the existing LED filament light core and metal wire, and creatively the LED filament electrodes directly is connected to each other.