Light Bulb Cap Electrical Connection Structure for Automated Assembly
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Solution Overview
Problem
Current LED bulb manufacturing involves costly and complex manual welding between bulb head electrodes and driver plates, making automated manufacturing challenging.
Innovation Solution
An electrical connection structure for the light bulb cap featuring a socket base on the driver plate with a first electrode having a fixing end electrically connected to the driver plate, allowing for elastic connection without welding, facilitating easier assembly and automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual welding is used to connect bulb head electrodes and driver plates, then electrical connection reliability is improved, but manufacturing cost increases and automation becomes difficult
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical pressing system. The bulb head electrode and driver plate are connected through direct mechanical contact and pressing force, eliminating the need for welding equipment and processes. This substitution maintains electrical connection reliability while enabling automated manufacturing and reducing costs.
Solution Approach 2:
The patent introduces a pressing mechanism as an intermediary between the bulb head electrode and driver plate. This intermediary component facilitates the connection by applying controlled pressure to ensure good electrical contact without requiring welding. The pressing mechanism can be easily automated and integrated into manufacturing lines.
2Reliability
If manual welding process is used, then electrical connection is achieved, but assembly complexity and time increase
Solution Approach 1:
The complex welding process is replaced with a simple mechanical pressing operation. The connection is achieved by applying pressure to bring the electrode and driver plate into direct contact, eliminating multiple welding steps, equipment setup, and post-welding inspections. This dramatically simplifies the assembly process while maintaining reliable electrical connection.
Solution Approach 2:
The patent separates the connection function from the welding process. The pressing mechanism is designed as a distinct, modular component that can be independently controlled and optimized. This segmentation allows for easier integration into automated assembly lines and simplifies the overall manufacturing system.
3Reliability
If welding is used for electrode connection, then strong electrical bond is formed, but manufacturing productivity decreases
Solution Approach 1:
The time-consuming welding process is replaced with a rapid mechanical pressing operation. The pressing mechanism can quickly establish electrical contact between components without requiring heat application, cooling periods, or complex process control. This dramatically increases manufacturing throughput while maintaining adequate electrical bond strength for LED bulb operation.
Solution Approach 2:
The patent designs the pressing mechanism to pre-position and pre-align the electrode and driver plate before applying the final connecting pressure. This preliminary action ensures that components are correctly oriented and spaced, eliminating the need for post-connection adjustments and rework. The entire connection process can be completed in a single automated pressing cycle, maximizing productivity.
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 solution reduces manufacturing costs and simplifies the assembly process, enabling more efficient and automated production of LED bulbs by eliminating the need for welding.
Implementation Method 1
it is only needed to elastically about the connecting end of the first electrode on the sidewall of the first electrode terminal to achieve electrical connection
Data Source
Figure 1
Figure 2~4
AI summary
An electrical connection structure of a light bulb cap comprises a driving board (10) and a light bulb cap body (20) comprising a casing structure open at a top thereof and a side wall forming a first electrode terminal (20), wherein the driving board (10) comprises a bottom arranged at an inner side of the light bulb cap body (20). The electrical connection structure of a light bulb cap further comprises a connection socket (40) and a first electrode (50). The connection socket (40) is fixed on the driving board (10) and provided thereon with an insertion track (41). The first electrode (50) comprises a fixed terminal (51) and a connection terminal (52). The fixed terminal (51) of the first electrode (50) is electrically connected to the driving board (10) through the insertion track (14). The connection terminal (52) of the first electrode (50) comprises an elastic structure and is configured to elastically press against an inner wall of the first electrode terminal (30). The electrical connection structure of the light bulb cap has advantages of being simple in structure and easy to assemble in automatic assembly.