Modular LED Lamp with Serial Connection for Cost Reduction
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Solution Overview
Problem
Conventional LED lamps for different tube lengths are manufactured as distinct products, increasing costs and complicating product management due to differences in substrate length and LED count.
Innovation Solution
An LED lamp design featuring elongated LED units with serial connection capabilities and standardized bases for power attachment, allowing multiple units to be connected for varying lengths, using a coupler and bridge rectifier circuits for efficient power distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If LED lamps for different tube lengths are manufactured as distinct products with different substrate lengths and LED counts, then the lighting performance can be optimized for each length, but the manufacturing cost increases and product management becomes complicated
Solution Approach 1:
The LED lamp is divided into multiple identical LED modules that can be independently manufactured and then connected in series. Each module contains the same substrate length and LED count, but by varying the number of modules connected, different total lengths are achieved. This segmentation allows standardized mass production of individual modules while providing flexibility in final product configuration.
Solution Approach 2:
A universal LED module design is created that can serve multiple purposes by simply changing the number of modules connected in series. The same module type can be used to create lamps of various lengths (e.g., 580mm, 1198mm) by connecting 1, 2, or more modules accordingly. This universality eliminates the need for multiple specialized product lines.
2Illumination intensity
If multiple types of LED lamps with different substrate lengths and LED counts are produced, then specific lighting requirements for different lengths are met, but manufacturing cost increases
Solution Approach 1:
The lamp system is segmented into identical, standardized LED modules that can be mass-produced using the same manufacturing process. This eliminates the need for separate production lines for different lamp lengths, thereby reducing manufacturing costs while still allowing customization through modular assembly.
Solution Approach 2:
Multiple identical LED modules are merged/connected in series to create lamps of different total lengths. Instead of manufacturing different lamps separately, the same module is combined in different quantities to meet various lighting requirements, achieving cost efficiency through economies of scale in module production.
3Illumination intensity
If distinct products are manufactured for different tube lengths with different substrate and LED configurations, then optimal lighting for each length is achieved, but product management becomes complicated
Solution Approach 1:
A universal LED module design serves multiple product configurations. The same module type can be used across different lamp lengths and applications, simplifying inventory management, quality control, and after-sales service. Product management becomes easier because there is essentially one product design to manage rather than multiple distinct designs.
Solution Approach 2:
By segmenting the lamp into standardized modules, product management is simplified through modular inventory control. Instead of tracking multiple unique products with different specifications, the system tracks a single standardized module type, reducing complexity in supply chain management, stocking, and distribution.
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 enables the production of LED lamps of different lengths using the same components, reducing manufacturing costs and simplifying product management while ensuring consistent lighting across different configurations.
Implementation Method 1
an AC/DC converter that converts AC to DC, provided between the electrodes and the external connection terminal
Implementation Method 2
at least one elongated LED unit including a plurality of light emitting diodes
Implementation Method 3
a plurality of light emitting diodes
Data Source
AI summary
An LED lamp A1 includes at least one elongated LED unit 1 including a plurality of light emitting diodes 13, and bases 2 and 3 configured to be attached to the ends of the LED unit 1 in the longitudinal direction to receive power from outside. The lamp is configured to allow a plurality of LED units 1 to be serially connected. Such configuration contributes to reducing the manufacturing cost and facilitating the management of the products, with respect to a plurality of types of products of different lengths.