Light Bulb Base With Riveted Thimble and Segmented Insulator
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Solution Overview
Problem
Conventional LED light bulbs have inefficient and costly fabrication processes due to customized molds for insulating plastic components, and they lack sufficient protection against external forces.
Innovation Solution
A cost-effective light bulb base featuring a cylinder-shaped insulating component, a conductive base connector, and a metal thimble, where the thimble rivets the connector to the insulating component, providing mutual insulation and increased strength without thickening the metal housing, and incorporating a heat-dissipating component for integrated structure fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating plastic material is injected into a customized mold to form the insulating plastic component, then the metal threaded housing is separated from the metal thimble, but the fabrication process becomes inefficient and expensive
Solution Approach 1:
The insulating component is divided into two separate parts: a first insulating component forming the light bulb base and a second insulating component forming the socket. This segmentation allows each component to be manufactured independently using standard molds, eliminating the need for complex customized molds while maintaining the insulation function between metal components.
Solution Approach 2:
The first insulating component serves multiple functions: it forms the light bulb base structure, provides electrical insulation between the metal threaded housing and metal thimble, and integrates the second insulating component within its cavity. This multi-functionality simplifies the overall manufacturing process by combining several functions into a single primary component.
2Strength
If the insulating plastic component is thickened to provide sufficient protection against external force, then protection is improved, but the fabrication cost increases significantly
Solution Approach 1:
The invention uses a composite structure combining two different insulating materials: a first insulating material (such as rubber or plastic) for the base component and a second insulating material (such as epoxy resin or phenolic resin) for the socket component. This composite approach provides sufficient mechanical strength and protection against external forces while maintaining cost-effectiveness through the use of standard manufacturing molds.
3Strength
If the metal threaded housing is thickened or high-hardness metals are applied to improve protection, then protection is enhanced, but the fabrication cost increases
Solution Approach 1:
The invention introduces insulating components as intermediary elements between the metal threaded housing and metal thimble. These insulating components (first and second insulating components) provide mechanical protection and electrical insulation without requiring the metal housing to be thickened or made from high-hardness metals, thereby reducing fabrication costs while maintaining protection capability.
4Reliability
If a customized mold is used to fabricate the insulating plastic component, then the component can separate metal components, but the mold preparation becomes expensive
Solution Approach 1:
The insulation system is segmented into two separate components manufactured in two different standard molds. The first insulating component is formed in a first standard mold, and the second insulating component is formed in a second standard mold. This segmentation eliminates the need for expensive customized molds while maintaining the separation function between metal components.
Solution Approach 2:
The invention uses standard, readily available mold designs rather than custom-designed molds. By copying proven standard mold geometries for the first and second insulating components, the invention avoids the high cost of mold preparation while ensuring proper separation and insulation functions.
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
The solution enables simpler and more cost-effective assembly, enhanced protection against external forces, and efficient heat dissipation, reducing fabrication costs and complexity while maintaining performance.
Implementation Method 1
The metal thimble inserts into the jack at its first side via the circumferential interior bore. Such that the metal thimble rivets the base connector to the insulating component.
Implementation Method 2
Both the base connector and the metal thimble are made of conductive materials. The cylinder-shaped insulating component separates the base connector and the metal thimble in a mutually-insulated manner.
Implementation Method 3
a heat-dissipating component, which is coupled to a second side of the cylinder-shaped insulating component
Data Source
AI summary
A light bulb base includes a cylinder-shaped insulating component, a cylinder-shaped base connector, a metal thimble and a heat-dissipating component. The insulating component has a jack at its first side. The base connector has a circumferential interior bore extending there through. The interior bore accommodates the insulating component at a first side of the base connector. The metal thimble inserts into the jack at its first side via the interior bore. Such that the metal thimble rivets the base connector to the insulating component. The heat-dissipating component has a first side coupled to a second side of the insulating component. The heat-dissipating component includes a first opening at its second side. The heat-dissipating component also includes a cavity chamber disposed inside the first opening.