LED Lighting Fixture Radial Strip Assembly
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Solution Overview
Problem
Existing LED lighting fixtures have inefficient heat dissipation and assembly issues, leading to inadequate illumination and high production costs due to the directional light emission and complex assembly processes.
Innovation Solution
A method involving cutting a flat blank to form a patterned flat plate with radially extending peripheral extensions, forming a patterned circuit, bringing LED dies into electrical contact, and bending the plate to form a shell that allows LED dies to be oriented in various directions, enhancing heat dissipation and simplifying assembly by press-fitting an insert segment into a lamp base.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If LED dies are mounted on a horizontal lamp body carrier board unit, then the assembly process is simple, but light travels mainly in one direction so that some areas are not sufficiently illuminated and heat dissipation is inefficient
Solution Approach 1:
The lamp body is divided into multiple strips arranged in a radiating manner around the central luminous unit. Each strip can be independently assembled and then locked together, simplifying the overall assembly process while enabling multi-directional light emission for better illumination coverage.
Solution Approach 2:
The strips are arranged radially in a planar configuration around the central luminous unit, transitioning from a single vertical mounting direction to a multi-directional radial arrangement. This dimensional change enables light to be emitted in multiple directions simultaneously, improving illumination coverage without significantly complicating the assembly process.
2Strength
If the combining unit is mechanically connected to strips through locking sleeve and rivets, then the connection is secure, but the assembly process is time-consuming and production cost is high
Solution Approach 1:
The locking sleeve and rivet functions are merged into a single integrated snap-fit connection mechanism. The combining unit features elastic arms with snap-fit ends that directly engage with grooves on the strips, eliminating the need for separate locking sleeves and rivets. This integration maintains secure connection strength while dramatically reducing assembly steps and production cost.
Solution Approach 2:
The elastic arms with snap-fit ends provide self-locking functionality through their inherent elasticity. When the strips are inserted into the combining unit, the elastic arms automatically deform and lock into place without requiring additional fastening operations. This self-service mechanism secures the connection while eliminating time-consuming manual assembly steps.
3Ease of manufacture
If a traditional lamp body structure is used, then manufacturing is straightforward, but heat dissipation from LED dies is insufficient
Solution Approach 1:
The lamp body structure serves multiple functions simultaneously: it provides the mechanical framework for mounting LED components, acts as a heat dissipation pathway through its metal construction, and enables multi-directional light emission through its radial strip arrangement. This multi-functionality improves heat dissipation efficiency without significantly complicating the manufacturing process.
Solution Approach 2:
The radial arrangement of strips around the central luminous unit creates a curved, three-dimensional heat dissipation pathway. Heat from the LED dies can conduct through the metal strips in multiple directions rather than being confined to a flat plane, improving heat dissipation efficiency while maintaining manufacturing simplicity through standard bending and forming operations.
Data Source
AI summary
A method for making an LED lighting fixture includes the steps of: a) cutting a flat blank to form a flat plate including a central piece having a central region and a circumferential region, and a plurality of peripheral extensions; b) forming on the flat plate a patterned circuit which includes a plurality of electrical contact pairs that are formed on the central piece or the peripheral extensions; c) bringing a plurality of LED dies into electrical contact with the electrical contact pairs, respectively; and d) bending the peripheral extensions rearwardly relative to the central piece and toward the central axis to form a shell.