Led light bulb and manufacturing method thereof

Abstract

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.

1 . An LED light bulb comprising:
 a bulb envelope having an opening, wherein a material of the bulb envelope comprises soda-lime glass;   a stem, the stem and the bulb envelope being melted at a high temperature, so that a side skirt of the stem is connected to the bulb envelope and seals the opening, wherein the stem has a supporting portion, and the supporting portion is located in the bulb envelope;   at least two conductors located through the stem; and   at least one LED light emitting module assembled to the supporting portion and coupled to the at least two conductors.   
     
     
         2 . The LED light bulb of  claim 1 , wherein the stem has a pipe, and the pipe has an open end in the bulb envelope and a sealed end facing an outside of the bulb envelope. 
     
     
         3 . The LED light bulb of  claim 1 , further comprising:
 fluid filling the bulb envelope.   
     
     
         4 . The LED light bulb of  claim 1 , wherein the bulb envelope is in a shape of a bottle with a flat bottom and extends along a central axis, and a projection length of the LED light emitting module on the central axis is greater than 40% of a projection length of the bulb envelope on the central axis. 
     
     
         5 . An LED light bulb comprising:
 a bulb envelope having an opening;   a stem connected to the bulb envelope and sealing the opening, the stem having a supporting portion located in the bulb envelope;   at least two conductors located through the stem;   at least one LED light emitting module assembled to the supporting portion and coupled to the at least two conductors; and   a supporting bracket assembled to the supporting portion and leaning against the bulb envelope, the supporting bracket having a trunk and a plurality of branches, the trunk extending from the supporting portion, the LED light emitting module being assembled to the trunk, the plurality of branches extending from one end of the trunk and respectively contacting the bulb envelope, wherein the number of contacts between the supporting bracket and the bulb envelope is equal to or greater than 2, and a maximum linear distance among the contacts is greater than a maximum inner diameter of the opening.   
     
     
         6 . The LED light bulb of  claim 5 , wherein the bulb envelope has a sidewall and a bottom wall connected to the sidewall at an intersection, and at least one of the contacts of the supporting bracket and the bulb envelope is located at the intersection. 
     
     
         7 . The LED light bulb of  claim 5 , wherein a material of the bulb envelope comprises soda-lime glass. 
     
     
         8 . The LED light bulb of  claim 5 , wherein the stem has a pipe, and the pipe has an open end inside the bulb envelope and a sealed end facing an outside of the bulb envelope. 
     
     
         9 . The LED light bulb of  claim 5 , further comprising:
 fluid filling the bulb envelope.   
     
     
         10 . The LED light bulb of  claim 5 , wherein the bulb envelope is in a shape of a bottle with a flat bottom and extends along a central axis, and a projection length of the LED light emitting module on the central axis is greater than 40% of a projection length of the bulb envelope on the central axis. 
     
     
         11 . An LED light bulb comprising:
 a bulb envelope having an opening;   a stem connected to the bulb envelope and sealing the opening, the stem having a supporting portion and a pipe, the supporting portion being located in the bulb envelope, the pipe having an open end inside the bulb envelope and a sealed end outside the bulb envelope;   at least two conductors located through the stem;   at least one LED light emitting module assembled to the supporting portion and coupled to the at least two conductors; and   fluid filling the bulb envelope,   wherein the bulb envelope is in a shape of a bottle and extends along a central axis, and a projection length of the LED light emitting module on the central axis is greater than 40% of a projection length of the bulb envelope on the central axis.   
     
     
         12 . The LED light bulb of  claim 11 , wherein a material of the bulb envelope comprises soda-lime glass. 
     
     
         13 . The LED light bulb of  claim 11 , further comprising:
 a supporting bracket assembled to the supporting portion and leaning against the bulb envelope, wherein the number of contacts between the supporting bracket and the bulb envelope is equal to or greater than 2, and a maximum linear distance among the contacts is greater than a maximum inner diameter of the opening.   
     
     
         14 . The LED light bulb of  claim 11 , wherein the bulb envelope has a sidewall and a bottom wall connected to the sidewall at an intersection, and at least one of the contacts of the supporting bracket and the bulb envelope is located at the intersection. 
     
     
         15 . The LED light bulb of  claim 11 , wherein the supporting bracket has a trunk and a plurality of branches, the trunk extends from the supporting portion, the LED light emitting module is assembled to the trunk, and the plurality of branches extends from one end of the trunk and respectively contacting the bulb envelope. 
     
     
         16 . The LED light bulb of  claim 11 , wherein a material of the bulb envelope comprises soda-lime glass. 
     
     
         17 . The LED light bulb of  claim 1 , further comprising:
 a bulb head assembled to the bulb envelope and coupled to the at least two conductors.   
     
     
         18 . The LED light bulb of  claim 1 , wherein the number of the LED light emitting module is equal to or greater than 2, and the LED light emitting modules are connected in series or in parallel. 
     
     
         19 . The LED light bulb of  claim 1 , wherein the LED light emitting module is a rigid LED light emitting module or a flexible LED light emitting module. 
     
     
         20 . (canceled) 
     
     
         21 . (canceled) 
     
     
         22 . (canceled) 
     
     
         23 . The LED light bulb of  claim 1 , further comprising:
 an outer bulb casing surrounding the bulb envelope, so that the outer bulb casing and the bulb envelope together form a layered space surrounding the bulb envelope; and   liquid located in the layered space.   
     
     
         24 . The LED light bulb of  claim 1 , wherein the bulb envelope has a standing portion providing a standing function. 
     
     
         25 . A manufacturing method of an LED light bulb, comprising:
 positioning a stem and at least one LED light emitting module of a supporting portion assembled to the stem in a bulb envelope through an opening of the bulb envelope, wherein the LED light emitting module is coupled to and located through at least two conductors of the stem;   pre-heating the opening of the bulb envelope and a portion of a neck portion adjacent to the opening for a pre-heating time period, so that a temperature at which the opening and the neck portion are heated is a pre-heating temperature;   after the pre-heating step, main-heating the opening of the bulb envelope and the portion of the neck portion adjacent to the opening, 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 to seal the opening of the bulb envelope, wherein the main-heating temperature is higher than the pre-heating temperature;   after the main-heating step, pumping residual air from the bulb envelope through a pipe of the stem;   after the air-pumping step, introducing fluid into the bulb envelope through the pipe of the stem; and   after the gas-introducing step, sealing the pipe, so that the bulb envelope is in an airtight state.   
     
     
         26 . The manufacturing method of  claim 25 , further comprising:
 after sintering the side skirt of the stem to the bulb envelope, post-heating the opening of the bulb envelope and the neck portion for a post-heating time period, so that the temperature at which the opening and the neck portion are heated is a post-heating temperature.   
     
     
         27 . The manufacturing method of  claim 26 , wherein the post-heating temperature is lower than or equal to the pre-heating temperature. 
     
     
         28 . The manufacturing method of  claim 25 , further comprising:
 assembling a bulb head to the bulb envelope, the bulb head being coupled to the at least two conductors.   
     
     
         29 . The manufacturing method of  claim 25 , wherein a material forming the bulb envelope is soda-lime glass. 
     
     
         30 . The manufacturing method of  claim 25 , wherein a length of the portion of the neck portion adjacent to the opening is greater than half a maximum inner diameter of the opening. 
     
     
         31 . The LED light bulb of  claim 5 , further comprising:
 a bulb head assembled to the bulb envelope and coupled to the at least two conductors.   
     
     
         32 . The LED light bulb of  claim 5 , wherein the number of the LED light emitting module is equal to or greater than 2, and the LED light emitting modules are connected in series or in parallel. 
     
     
         33 . The LED light bulb of  claim 5 , wherein the LED light emitting module is a rigid LED light emitting module or a flexible LED light emitting module. 
     
     
         34 . The LED light bulb of  claim 5 , further comprising:
 an outer bulb casing surrounding the bulb envelope, so that the outer bulb casing and the bulb envelope together form a layered space surrounding the bulb envelope; and   liquid located in the layered space.   
     
     
         35 . The LED light bulb of  claim 5 , wherein the bulb envelope has a standing portion providing a standing function. 
     
     
         36 . The LED light bulb of  claim 11 , further comprising:
 a bulb head assembled to the bulb envelope and coupled to the at least two conductors.   
     
     
         37 . The LED light bulb of  claim 11 , wherein the number of the LED light emitting module is equal to or greater than 2, and the LED light emitting modules are connected in series or in parallel. 
     
     
         38 . The LED light bulb of  claim 11 , wherein the LED light emitting module is a rigid LED light emitting module or a flexible LED light emitting module. 
     
     
         39 . The LED light bulb of  claim 11 , further comprising:
 an outer bulb casing surrounding the bulb envelope, so that the outer bulb casing and the bulb envelope together form a layered space surrounding the bulb envelope; and   liquid located in the layered space.   
     
     
         40 . The LED light bulb of  claim 11 , wherein the bulb envelope has a standing portion providing a standing function. 
     
     
         41 . The LED light bulb of  claim 3 , wherein the fluid is non-conductive fluid. 
     
     
         42 . The LED light bulb of  claim 3 , wherein the fluid is inert gas. 
     
     
         43 . The LED light bulb of  claim 3 , wherein the fluid is helium gas. 
     
     
         44 . The LED light bulb of  claim 9 , wherein the fluid is non-conductive fluid. 
     
     
         45 . The LED light bulb of  claim 9 , wherein the fluid is inert gas. 
     
     
         46 . The LED light bulb of  claim 9 , wherein the fluid is helium gas. 
     
     
         47 . The LED light bulb of  claim 11 , wherein the fluid is non-conductive fluid. 
     
     
         48 . The LED light bulb of  claim 11 , wherein the fluid is inert gas. 
     
     
         49 . The LED light bulb of  claim 11 , wherein the fluid is helium gas.