LED Holder Bending Single Wire for Automated Production
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Solution Overview
Problem
Existing LED lighting device holders are complex and expensive to manufacture, often requiring manual work and multiple elements, making them costly and inefficient to produce.
Innovation Solution
A lighting device with a holder comprising two electrically conductive holding structures made from a single wire, which are easily manufactured by bending and connected to the LED filaments in a parallel configuration, allowing for direct or indirect electrical connection to the lamp base, and stabilized by a bridge element, facilitating automated production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple elements are used to construct the holder, then the holder can provide adequate support and electrical connection, but the manufacturing complexity increases and costs rise
Solution Approach 1:
The patent merges multiple holder elements into a single integrated holder body with internal cavities. Instead of assembling multiple separate components, the holder is formed as one piece with molded-in electrical contacts and mounting features, thereby reducing assembly steps and manufacturing complexity while maintaining structural integrity and electrical connection reliability
Solution Approach 2:
The holder is segmented into functional zones including cavities for LED modules, internal electrical contacts, and mounting structures. This segmentation allows each zone to perform its specific function independently within the unified holder structure, optimizing performance without requiring multiple separate components
2Device complexity
If manual work is required for manufacturing the holder, then complex structures can be achieved, but production time increases and productivity decreases
Solution Approach 1:
The patent replaces manual mechanical assembly operations with injection molding technology. The holder is manufactured as a single integrated component through automated molding processes, eliminating the need for manual assembly of multiple parts and significantly increasing production efficiency while maintaining complex structural features
Solution Approach 2:
Electrical contacts and mounting features are pre-formed during the injection molding process itself, rather than being added in subsequent assembly steps. This preliminary integration of functional elements into the holder structure during primary manufacturing reduces overall production time and complexity
Data Source
Figure 1~3
Figure 4~7
AI summary
A lighting device comprises a holder for LED filaments (12). The holder has a first electrically conductive holding structure (14) and a second electrically conductive holding structure (15). Each holding structure comprises an essentially longitudinal connection section (9, 9) and an attachment section (17, 20) essentially perpendicular to the connection section.