Soda-Lime Glass LED Bulb Stem Sealing and Thermal Stability
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Solution Overview
Problem
Conventional LED light bulbs made of materials like lead silicate glass or borosilicate glass lack visual appeal and stability due to their processing difficulties and thermal expansion issues, limiting the use of soda-lime glass in bulb manufacturing despite its low costs and diverse visual effects.
Innovation Solution
An LED light bulb design featuring a soda-lime glass bulb envelope with a stem and supporting bracket, where the stem seals the opening and conductors are used to secure the LED light emitting module, and a manufacturing method involving pre-heating, sintering, and filling with non-conductive fluid to ensure stability and airtightness, allowing for a bulb shape that enhances visual effects and light emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If soda-lime glass is used for bulb envelope, then manufacturing cost is reduced and visual effects are enhanced, but thermal expansion issues and processing difficulties arise
Solution Approach 1:
The patent changes the material parameter from conventional lead silicate glass or borosilicate glass to soda-lime glass, accepting its higher thermal expansion coefficient in exchange for lower manufacturing cost and superior visual effects. This parameter change is made possible by配套 design adjustments in the supporting bracket structure.
Solution Approach 2:
The supporting bracket acts as an intermediary component that compensates for the thermal expansion characteristics of soda-lime glass. The bracket's design with multiple contact points and specific structural features helps accommodate thermal expansion while maintaining the bulb envelope's stability and positioning.
2Shape
If soda-lime glass is used for bulb envelope, then visual appeal is enhanced, but processing difficulties increase
Solution Approach 1:
The patent utilizes the optical and visual parameters of soda-lime glass, which offers superior clarity, color rendering, and visual appeal compared to conventional glass materials. The design embraces these visual advantages while managing the material's processing characteristics through appropriate structural design.
Solution Approach 2:
The supporting bracket serves as a mediator that simplifies the assembly and positioning process of the soda-lime glass bulb envelope. By providing a structured framework with multiple contact points, the bracket makes handling and assembly easier despite the glass material's processing challenges.
3Stability of the object's composition
If supporting bracket with multiple contacts is used, then stability is improved, but device complexity increases
Solution Approach 1:
The supporting bracket is segmented into multiple contact points distributed across different locations on the bulb envelope. This segmentation provides stable positioning through multiple support points while keeping each individual contact point simple in design. The trunk and branches structure divides the support function into manageable segments.
Solution Approach 2:
The supporting bracket performs multiple functions simultaneously: it provides mechanical support, positions the bulb envelope, accommodates thermal expansion, and facilitates assembly. This multi-functionality reduces the need for additional separate components, thereby managing overall device complexity while achieving high stability.
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 use of soda-lime glass bulb envelopes with a supporting bracket and specific manufacturing steps enhances visual appeal, stability, and light emission patterns, overcoming thermal expansion issues and providing richer visual effects while maintaining low manufacturing costs.
Implementation Method 1
The stem is connected to the bulb envelope and seals the opening
Implementation Method 2
The opening of the bulb envelope and a portion of a neck portion adjacent to the opening are pre-heated for a pre-heating time period
Implementation Method 3
the opening of the bulb envelope and the portion of a neck portion adjacent to the opening are heated, so that the temperature at which the opening and the neck portion are heated is a main-heating temperature, and a side skirt of the stem is simultaneously sintered to the bulb envelope
Implementation Method 4
fluid fills the bulb envelope
Data Source
AI summary
A LED light bulb includes a bulb envelope, a stem, at least two conductors, at least one LED light emitting module, and fluid. The bulb envelope has an opening, and a material of the bulb envelope includes soda-lime glass. The stem is connected to the bulb envelope and seals the opening. Here, the stem has a supporting portion and a pipe, the supporting portion is located in the bulb envelope, and the pipe has an open end inside the bulb envelope and a sealed end outside the bulb envelope. The conductors are located through the stem. The LED light emitting module is assembled to the supporting portion and coupled to the conductors. The fluid fills the bulb envelope. The bulb envelope made of soda-lime glass enhances visual effects produced by the shape, color and light reflection of the LED light bulb.