Light Source Bracket with Pressed COB Electrical Contacts
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Solution Overview
Problem
Conventional COB modules require secondary heating for welding, leading to thermal expansion and contraction, affecting the lifespan of luminescent gold wires and increasing defect rates and costs.
Innovation Solution
A light source bracket with a positioning plate and double-sided aluminum substrate that electrically connects the COB module without welding, using conductive protrusions to stabilize the connection and avoid thermal issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If secondary heating is performed for welding wires on the COB module, then electrical connection between COB module and PCB is achieved, but thermal expansion and contraction occurs causing reduced lifespan of luminescent gold wires and increased defect rate
Solution Approach 1:
The patent extracts the heating process from the connection establishment process. Instead of heating during welding, the connection is established through mechanical pressing at room temperature, completely removing the harmful thermal effect from the manufacturing process.
Solution Approach 2:
The patent replaces the thermal welding system with a mechanical pressing system. Conductive protrusions on the aluminum substrate mechanically press against the COB module to establish electrical connection, substituting thermal energy with mechanical force.
2Ease of manufacture
If secondary heating is performed for welding wires on the COB module, then electrical connection is achieved, but production costs increase due to increased loss and defect rate
Solution Approach 1:
The aluminum substrate with conductive protrusions serves dual functions: it provides structural support and simultaneously establishes electrical connection through the protrusions that press against the COB module electrodes, eliminating the need for separate welding operations.
Solution Approach 2:
The double-sided aluminum substrate performs multiple functions: heat dissipation, mechanical support, and electrical connection. The conductive protrusions integrate the electrical connection function into the structural component, reducing the need for additional materials and processes.
3Ease of manufacture
If secondary heating is performed for welding wires on the COB module, then electrical connection is achieved, but energy consumption increases
Solution Approach 1:
The patent replaces the thermal welding system with a mechanical pressing system. Conductive protrusions on the aluminum substrate mechanically press against the COB module to establish electrical connection, substituting thermal energy with mechanical force.
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
Reduces loss and improves yield rates while lowering production costs and energy consumption, enhancing the COB module's lifespan and environmental friendliness.
Implementation Method 1
a pair of conductive protrusions is arranged on a side of the double-sided aluminum substrate facing the COB module, and respectively pressed onto positive and negative electrodes of the COB module to electrically connect the COB module and the double-sided aluminum substrate
Implementation Method 2
a double-sided aluminum substrate pressed onto the positioning plate and the COB module; a plurality of locking elements passing through the double-sided aluminum substrate and the positioning plate to fix all of the double-sided aluminum substrate, the COB module and the positioning plate to the heat sink
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present disclosure provides a light source bracket (20) and a lamp thereof, and the light source bracket (20) includes a positioning plate (21) attached on a heat sink (10) and including a receiving room (211) for receiving a COB module (30) therein, and a double-sided aluminum substrate (22) pressed onto the positioning plate (21) and the COB module (30); a plurality of locking elements (40) passing through the double-sided aluminum substrate (22) and the positioning plate (21) to fix all of the double-sided aluminum substrate (22), the COB module (30) and the positioning plate (21) to the heat sink (10). A pair of conductive protrusions (221) is arranged on a side of the double-sided aluminum substrate (22) facing the COB module (30), and respectively pressed onto positive and negative electrodes of the COB module (30) to electrically connect the COB module (30) and the double-sided aluminum substrate (22).