LED Lamp Sheet-Shaped Inner Support for Simplified Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing LED lamp manufacturing process is complex and costly, requiring intricate assembly of glass frames and conductors, leading to high production costs and long times, which are not compatible with high-frequency production needs, and the lamps are not resistant to impacts or offering sufficient creative freedom for designers.
Innovation Solution
A LED lamp design featuring a sheet-shaped inner support directly attached to the attachment body, with LED filaments and conductors printed or co-printed on the support, eliminating the need for additional connection elements and allowing for a simpler, more robust, and aesthetically clean construction, while providing increased creative freedom in design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the traditional glass frame structure with multiple components (column, stars, radial elements) is used to support LED filaments, then the lamp achieves structural stability and aesthetic appearance, but the manufacturing complexity increases significantly and production time extends
Solution Approach 1:
The patent merges multiple separate components (column, stars, radial elements) into a single integrated sheet-shaped support body. This support body is formed from a single sheet of transparent material through bending and folding operations, eliminating the need for separate assembly of multiple glass components while maintaining structural stability for holding LED filaments.
Solution Approach 2:
The invention uses a thin sheet-shaped support body made from a flexible or bendable transparent material (such as glass or plastic sheet). This thin film approach allows the support structure to be formed through simple bending and folding operations rather than complex assembly of rigid components, significantly reducing manufacturing complexity.
2Reliability
If the intricate assembly process with multiple connection elements is used to attach LED filaments to the glass frame, then the lamp achieves reliable electrical connections, but the production cost increases and manufacturing speed decreases
Solution Approach 1:
The patent combines the support structure and electrical connection elements into a single integrated sheet-shaped support body. Conductors are embedded within or attached to the sheet before bending, eliminating the need for separate connection operations during assembly. This integration maintains reliable electrical connections while enabling much faster production.
Solution Approach 2:
The conductors and support structure are prepared and positioned in advance on the flat sheet before the bending and folding operations. This preliminary arrangement of electrical connections eliminates the need for complex connection operations during final assembly, significantly increasing production speed while maintaining connection reliability.
3Manufacturing precision
If the traditional multi-component glass frame is assembled with precise alignment of radial elements and stars, then the lamp achieves precise positioning of LED filaments, but the manufacturing precision requirements increase and costs rise
Solution Approach 1:
The sheet-shaped support body can be precisely bent and folded to create the required three-dimensional structure with accurate positioning features. This forming process from a single sheet provides inherent geometric precision without requiring the high-precision assembly of multiple separate components, making manufacturing easier while maintaining positioning accuracy.
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 design simplifies and accelerates production, reduces costs, enhances mechanical resistance, and offers greater design flexibility, enabling quicker and more affordable manufacturing of LED lamps with improved durability and creative possibilities.
Implementation Method 1
a resilient mounting member having a modulus of elasticity between 0.5-5.0 MPa that is mounted in the recess and having the LED chip mounted on the resilient mounting member with the peripheral side of the LED chip mounted against the resilient mounting member
Implementation Method 2
an LED chip that is mounted on the resilient mounting member
Data Source
Figure 1~3
Figure 4~8
Figure 9
AI summary
A LED lamp (1) comprising an attachment body (2) comprising electrical contacts (3); an inner support (4) for LED filaments fastened to said attachment body (2); at least one LED filament (6, 6', 7, 7') fastened to said inner support (4), electrical conductors (8) connected between said electrical contacts (3) and said at least one LED filament (6, 6', 7, 7') for electrically powering said at least one LED filament (6, 6', 7, 7'),"in which said inner support (4) for LED filaments comprises a sheet-shaped body (5) fastened to said attachment body (2); said at least one LED filament (6, 6', 7, 7') being fastened to said sheet-shaped body (5) so as to adhere directly to said sheet-shaped body (5).