Modular Light Bulb with Releasable Connections for Serviceability
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Solution Overview
Problem
Traditional light bulbs are manufactured in a permanent manner, leading to waste when they break, as components have different lifespans and cannot be easily replaced or recycled.
Innovation Solution
A modular light bulb design featuring a light source unit, optical unit, driver unit, base unit, and chassis unit with releasable connections, allowing for assembly and disassembly without adhesives or soldering, enabling individual component replacement and recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If permanent assembly with adhesive and soldering is used, then structural strength and electrical connection reliability are improved, but repairability and component replaceability deteriorate
Solution Approach 1:
The light bulb is divided into distinct modular components (base unit, driver unit, light source unit, optical unit) that can be independently replaced. Each unit is connected through releasable mechanical and electrical connections, allowing selective replacement of faulty components without discarding the entire bulb assembly.
Solution Approach 2:
The connection system transitions from permanent static bonding (adhesive/soldering) to dynamic releasable connections. Mechanical features such as snap-fits, clips, and plug-socket interfaces enable components to be easily attached and detached, providing adaptability for repair and replacement while maintaining reliable connections during operation.
2Manufacturing precision
If permanent assembly with adhesive and soldering is used, then manufacturing precision is improved, but waste generation and material loss worsen
Solution Approach 1:
By segmenting the bulb into replaceable modules, only the faulty component needs to be discarded and replaced, rather than the entire assembly. This significantly reduces material waste when a component fails, as the functional units (base, driver, optical elements) can be retained and reused.
Solution Approach 2:
The modular design enables recovery and reuse of functional components. When a light source unit fails, it can be replaced while the driver unit, base unit, and optical unit are recovered and continue to function, eliminating the need to discard working components and reducing overall material waste.
3Reliability
If multiple soldering points and adhesives are used, then electrical connection reliability is improved, but device complexity and manufacturing complexity worsen
Solution Approach 1:
The complex soldering and adhesive bonding processes are extracted and replaced with simpler mechanical connection systems. Plug-socket electrical interfaces and mechanical snap-fits eliminate the need for multiple soldering points and adhesive applications, reducing manufacturing complexity while maintaining reliable electrical and mechanical connections.
Solution Approach 2:
Chemical bonding mechanisms (adhesives) and thermal bonding (soldering) are replaced with mechanical connection systems. This substitution simplifies the assembly process, reduces manufacturing steps, and eliminates the need for specialized equipment while providing reliable reversible connections.
4Stability of the object's composition
If permanent assembly is used, then structural stability is improved, but adaptability and upgradability worsen
Solution Approach 1:
The structural connection system is designed to be dynamically reversible rather than permanently fixed. Mechanical features provide stable connections during normal operation while enabling easy disassembly for upgrades or modifications, allowing the bulb configuration to be adapted to different requirements.
Solution Approach 2:
The base unit and connection interfaces are designed with universal compatibility, allowing different light source units and optical units to be interchangeably mounted on the same base. This enables users to upgrade components or adapt the bulb for different applications without replacing the entire assembly.
Data Source
AI summary
A modular light bulb and a method of assembling it are disclosed. The modular light bulb comprises a light source unit, an optical unit enclosing the light source unit, a driver unit configured to drive the light source unit, a base unit engageable with a light bulb socket, and a chassis unit. The driver unit is removably accommodated within the chassis unit and has a releasable electrical connection to the base unit and a releasable electrical connection to the light source unit passing through the base unit. The base unit is releasably fastened onto the chassis unit, the light source unit is releasably fastened onto the chassis unit, and the optical unit is releasably fastened onto the chassis unit.