Automating LED Assembly Processes for Efficiency

The LED light bulb design enables easy mass production and cost reduction while preserving the aesthetic appeal and illumination pattern of incandescent bulbs. It features unique internal component placement, advanced heat dissipation techniques, and optical diffusers to replicate the light output and appearance of traditional incandescent bulbs. This design allows for the efficient manufacturing of LED bulbs that closely mimic the look and light distribution of incandescent bulbs while offering the energy efficiency and longevity advantages of LED technology.

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Automating LED bulb production to improve efficiency and reduce costs. The process involves automated production steps using specialized machines instead of manual labor. The steps include manufacturing the glass core column with an integrated driving chip and resistor, automated welding of the LED wick filament, sealing the bulb, filling it with inert gas, cutting off the vent tube to make a rough bulb, and automatically installing the socket. The automated steps using specialized equipment replace manual labor for faster, more efficient production with lower costs.

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Efficient and cost-effective LED bulbs that replicate the optical performance and appearance of incandescent bulbs through strategic mechanical and optical design. LEDs are arranged on multiple sides of the bulb to emit light in various directions, complemented by reflective surfaces and diffusers to disperse and soften the light. This configuration achieves a more omnidirectional, incandescent-like light pattern without the need for complex optics. The design also incorporates simplified construction and robotic assembly techniques, reducing costs and enhancing mass production efficiency compared to traditional LED bulb designs.

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An LED light bulb with an optimized design for efficient assembly and reduced manufacturing costs. The bulb features multiple LED modules mounted on a central substrate, which is electrically connected to a driver board. The substrate includes contacts that interface with electrodes in the lamp cap. The driver board is housed within the bulb's radiator, streamlining the assembly process and minimizing production expenses.

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A LED light bulb that can be efficiently constructed in mass production for domestic and commercial lighting systems. The bulb design uses mechanical and electrical techniques to enable easy assembly using automated robotic techniques, reducing costs compared to traditional LED bulbs. The bulb has a main body with a threaded base and a stem that supports an LED array. The array includes LEDs arranged in a spherical pattern and angled to emit light in all directions similar to an incandescent bulb. The design allows the bulb to closely mimic the light output and appearance of incandescent bulbs while using LEDs.

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An automatic production process for LED bulbs that eliminates the need for manual labor, enabling fast, efficient, and high-quality production. The process uses automated machines and robotics to perform steps like manufacturing the inner core with chip and resistor, welding the LED filament, sealing the bulb, injecting inert gas, cutting off the vent, and attaching the socket.

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An LED lighting device with a holder that can be easily machine-made and reduces the shadowing of the LED filaments. The holder has two wire holding structures with connection sections and attachment sections. A non-conductive bridge element attaches between the two holding structures. The bridge element stabilizes the holder and prevents rotation.

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Filament LED light engine and lamp, and methods for automated manufacturing and forming of the light engine. The light engine uses multiple LED filament structures connected at a common apex to base contacts. The filaments provide their support structure, enabling a compact self-supporting design. The lamp uses this light engine in a housing to project light. The engine can be automated for mass production with methods like welding the filaments together on a mandrel.

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LED light bulb construction to allow easy mass production using automated robotic assembly techniques and reduce cost. The design includes a bulb housing with an integrated LED circuit board and heatsink that is detachable from the base. The base contains the power supply electronics and screw-type connector. This modular design allows the LED components to be easily assembled and replaced without complex fasteners or adhesives. The LED board has a reflective coating and is positioned to direct light toward the bulb housing for omnidirectional illumination. This allows an LED bulb to be constructed using efficient PCB assembly techniques and materials while achieving the appearance and light distribution of incandescent bulbs.

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LED filament lighting devices with an improved holder design that allows easy machine manufacturing. The holder has two wire structures connected by a non-conductive bridge piece. The wires are shaped to hold LED filaments. One wire has a radial section connecting the attachment and connection sections. The bridge stabilizes the wire positions. The holder can be machined as a single piece.

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A simplified method for manufacturing LED lamps that reduces assembly steps and costs while improving reliability compared to traditional screwing or gluing. The method involves connecting the components through a single extrusion coating step. The method includes inserting separately produced components like a driver housing, heat sink, and electronics into a mold. Then potting material is extrusion coated around them. This forms a secure and sealed connection between the components that are now permanently joined.

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A light engine for lamps that uses self-supporting filament LEDs. This allows automated construction and retrofitting into lamp bulbs. The light engine has multiple filament LEDs connected in series and attached at one end to base contacts. The filaments meet at a common apex. This leverages the LED frame structure to create a self-supporting light engine without auxiliary support structures.

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A LED light bulb designed for easy and efficient automated mass production that closely resembles the optical performance and appearance of an incandescent bulb. The bulb uses mechanical and electrical techniques that allow it to be constructed with cost-effective materials and manufacturing processes. The techniques include mounting the LED components on a single PCB, using a single heatsink, and orienting the LEDs to mimic the spherical light pattern of an incandescent bulb.

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LED light bulb assembly with simplified assembly and reduced parts count compared to prior art, for lower cost and more automated manufacturing. The assembly has a base with a socket connection and a holding portion facing in opposite directions. A substrate carrying the LEDs has a mounting section that attaches to the holding portion. The base and substrate abut in parallel when fully assembled. This allows the LEDs to be easily and securely mounted to the base without additional fixation means.

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A simplified, integrated heat sink assembly for LED lamps that reduces the number of electrical connections and enables automated assembly without sacrificing thermal management performance. The heat sink has two metallic components with integrated electrical contacts: a first component with a curved wall and hot contact, and a second component with a curved wall and neutral contact. These fit into an insulating plastic housing. The integrated design allows the lamp driver board's hot and neutral contacts to directly connect to the heat sink contacts, eliminating separate wiring steps.

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