LED ILLUMINATION APPARATUS AND MANUFACTURING METHOD THEREOF

Abstract

Disclosed are an LED illumination apparatus and its manufacturing method. A metal sheet is stamped to form a conductive plate with 3D space, and the conductive plate includes an illumination circuit, and a support frame for supporting the conductive plate to form different types of illumination apparatuses. The support frame is provided for supporting and fixing the conductive plate to facilitate the conductive plate to form a 3D curved surface, and an LED chip soldering point protection mechanism is provided for protecting each LED chip soldering point, so that the illumination apparatus is applicable for mass production to improve the yield rate and meet the high heat dissipation efficiency, large-range illumination, material saving, lightweight and/or environmental protection requirements.

Claims

1. An LED illumination apparatus, comprising: a conductive plate, being stamped to form a structure with 3D space, and having at least one electrode slot and a plurality of isolation slots, and each isolation slot dividing the conductive plate into a plurality of strip structures, and each strip structure forming a fixed planar structure and a plurality of fixing holes provided for mold pressing, wherein the fixed planar structure is disposed across the electrode slot, and each fixing hole is formed adjacent to an edge of the fixed planar structure; a plurality of LED chips, coupled and installed into the fixed planar structure of the conductive plate and across the electrode slot, and provided for dividing each strip structure into a plurality of parallel circuit areas of the LED chip, and a plurality of connecting portions or a strip structure being provided for connecting each parallel circuit area in series to form a series-parallel circuit; and a support frame, comprised of a plurality of strip support ribs and disposed in an internal space under the conductive plate, so that each fixing column may be passed and coupled to a fixing hole of the conductive plate, and a ventilation hole is formed between adjacent support ribs, and each support rib is configured to be corresponsive to a strip structure of the conductive plate; a support surface, extended between the support rib and each fixing column, and provided for attaching the bottom of each plane of the conductive plate, and used for mold pressing, and each fixing column being passed and extended to both sides of each LED chip to form an LED chip soldering point protection mechanism for protecting an electrode soldering point of each LED chip during a manufacturing process of the LED chip.

2. The LED illumination apparatus according to claim 1, wherein the illumination circuit has a series circuit isolated by each isolation slot, and each parallel circuit area is isolated by the electrode slot, and a connecting portion in the parallel circuit area is disposed across the isolation slot and provided for connecting a high potential electrode and a low potential of the plurality of LED chips in the area in parallel.

3. The LED illumination apparatus according to claim 1, wherein the conductive plate may dissipate heat with double large areas and the combined support frame also increases an additional heat dissipating area.

4. The LED illumination apparatus according to claim 1, further comprising a plurality of auxiliary portions coupled into the electrode slot to form a single-component conductive plate, and a fixed planar structure being formed between the fixing holes of the conductive plate, the periphery of the LED chip, and its non-opening area, and each group of fixing holes of the conductive plate and each group of fixing columns of each support rib being coupled to one another, and a support surface between each group of fixing columns attaching and abutting the bottom of the fixed planar structure, so that the electrode soldering point of each LED chip may be protected in each process to reduce the deformation of each LED chip electrode soldering point and improve the yield rate, and finally the plurality of auxiliary portions is removed to prevent a short circuit of the electrode and form a complete series-parallel circuit.

5. The LED illumination apparatus according to claim 1, wherein the low potential electrode of the electrode slot covers a heat transfer contact of each LED chip for accelerating the heat dissipation of each LED chip, when the electrode contact of each LED chip is soldered.

6. The LED illumination apparatus according to claim 1, wherein each fixing column is passed and extended into each fixing hole for connecting each fixing column, so that each fixing column may be fixed into the fixing hole by deformation or an adhesive.

7. The LED illumination apparatus according to claim 1, wherein when each strip structure is radially arranged, each connecting portion is disposed across the isolation slot to maintain an integral sheet structure of the conductive plate after the conductive plate is stamped and formed.

8. The LED illumination apparatus according to claim 7, further comprising a plurality of radial isolation slots for dividing the outermost portion of each strip structure into smaller strip structures, and a plurality of electrode slots for satisfying a circuit requirement.

9. The LED illumination apparatus according to claim 1, wherein when each strip structure is arranged parallelly, each electrode slot is disposed in the isolation slot, and when each electrode slot is arranged on both edges of the strip structure, the electrode slot is situated on the isolation slot to substitute the connecting portion by two middle strip structures, and plural groups of shorter conductive plates are connected in series to form a longer strip conductive plate.

10. The LED illumination apparatus according to claim 1, wherein when each strip structure is arranged parallelly, and the fixed planar structure is divided by each isolation slot, two adjacent strip structures form a plane and an electrode slot for mold pressing, and the plurality of electrode slots is arranged in the isolation slot; and each strip structure has a plurality of electrode slots, and the fixing holes of two adjacent strip structures are formed on both sides of the plane; a body of the middle strip structure may substitute each connecting portion to define a series connection between the parallel circuit areas of the LED chip.

11. The LED illumination apparatus according to claim 7, being used as a flat bulb lamp, characterized in that the conductive plate comprises a power contact, an electrode slot, a positioning portion, a plurality of connecting portions, a plurality of isolation slots, and a plurality of strip structures, wherein the plurality of isolation slots may divide the conductive plate into radially distributed strip structures; the conductive plate further comprising a plurality of heat conduction surfaces which are substantially circular shallow cup-shaped structures, and the heat conduction surface may be attached to an external circular surface of the support frame; each strip structure further comprises: a group of fixing holes, an electrode slot, a bending portion, and a plane of the fixed planar structure, wherein the group of fixing holes is disposed on both sides of the electrode slot; the bending portion is disposed on an outer periphery and attached to an external circular surface of the support frame after the bending portion is bent and formed; and the support frame being substantially a circular disc structure matched with the conductive plate and composed of a plurality of radially arranged strip support ribs, and each support rib having a group of fixing columns and the support surface disposed between the group of fixing columns, and each support surface matching with each group of fixing columns and being combined with a fixing hole of the conductive plate to support and fix a fixed planar structure of the conductive plate; a fixing ring installed to the center of the support frame and passing through a positioning portion of the conductive plate; and a latch slot being formed on an external circular surface of the support frame disposed around the periphery of an opening end.

12. The LED illumination apparatus according to claim 7, being used as a convexly curved surface bulb, characterized in that the conductive plate comprises a power contact, an electrode slot, a positioning portion, a plurality of connecting portions, a plurality of isolation slots, and a plurality of strip structures; wherein the plurality of isolation slots divides the conductive plate into a plurality of radially distributed strip structures; the conductive plate is in a shape of a hemispherical curved surface with an end composed of a spherical curved surface and a circular curved surface and the other end composed of a conical curved surface and a cylindrical surface to form a conical shape; a connecting portion, disposed across the isolation slot, being bent into a V-shape; each strip structure comprises: a plurality of bending portions, a group of fixing holes, an electrode slot, and a plane of the fixed planar structure; wherein the plurality of bending portions arranged in a direction from a cylindrical surface towards a spherical curved surface include a bending portion disposed between the cylindrical surface and the conical curved surface, a bending portion disposed between the circular curved surface and the conical curved surface, and a bending portion disposed on the spherical curved surface; one of the fixing holes is disposed on the spherical curved surface, and another fixing hole is disposed on the circular curved surface; the fixed planar structure and the electrode slot are disposed between the spherical curved surface and the circular curved surface and arranged at the middle of the group of fixing holes; and the support frame is a hemispherical structure, and each support rib has a group of fixing columns, and the support surface is disposed between each group of fixing columns, and each support surface matching each group of fixing columns is combined with a fixing hole of the conductive plate to support and fix a fixed planar structure of the conductive plate; a fixing ring, installed to the center of the support frame, and passing through a positioning portion of the conductive plate; and a latch slot formed on an external circular surface disposed at the external circumference of the support frame, and the external circular surface being attached closely to the circular curved surface of the conductive plate.

13. The LED illumination apparatus according to claim 7, being used as a concavely curved surface bulb, characterized in that the conductive plate comprises a power contact, an electrode slot, a positioning portion, a plurality of connecting portions, a plurality of isolation slots, and a plurality of strip structures; the plurality of isolation slots divides the conductive plate into a plurality of radially distributed strip structures; an end of the conductive plate has a concave hemispherical curved surface formed by a concave spherical surface and a concave circular curved surface, and the other end of the conductive plate in a conical shape formed by a conical curved surface and a cylindrical surface is bent into a V-shaped by the connecting portion connected and spanned across the isolation slot; each strip structure comprises a plurality of bending portions, a group of fixing holes, an electrode slot, and a plane of the fixed planar structure; the plurality of bending portions arranging in the direction from the cylindrical surface towards the concave spherical surface comprising a bending portion disposed between the cylindrical surface and the conical curved surface, a bending portion disposed between the concave circular curved surface and the conical curved surface, and a bending portion disposed on the concave spherical surface; wherein one of the fixing holes is disposed on the concave spherical surface and the other fixing hole is disposed on the concave circular curved surface, and the two fixing holes form a group; the fixed planar structure and the electrode slot are disposed between the concave spherical surface and the concave circular curved surface and disposed at the middle of the group of fixing holes; and the support frame is designed in a concave hemispherical structure and formed by a plurality of radially arranged support ribs, and each support rib has a group of fixing columns, and the support surface is formed between the group of fixing columns, and each support surface matched with each group of fixing columns is passed through and combined with each group of fixing holes, so as to support and fix the fixed planar structure of the conductive plate; and the center of the support frame has a fixing ring passing through a center hole of the positioning portion of the conductive plate; an external circular surface of the support frame disposed on an opening end has a latch slot, and the external circular surface is attached closely to a circular curved surface of the conductive plate, and an external circular surface disposed at the external circumference of the support frame is attached closely to the U-shaped bending portion of the conductive plate.

14. The LED illumination apparatus according to claim 8, being used as a hemispherical lamp, characterized in that the conductive plate comprises a power contact, a plurality of electrode slots, a positioning portion, a plurality of connecting portions, a plurality of isolation slots, and a plurality of strip structures, wherein the conductive plate is cut by the plurality of isolation slots to form a plurality of radially arranged strip structures; the conductive plate has an end being a hemispherical curved surface formed by the spherical curved surface and the circular curved surface, and the spherical curved surface has an electrode slot, and another electrode slot formed between the circular curved surface and the spherical curved surface; each strip structure has two radial sub-strip structures divided by the plurality of isolation slots and formed on the circular curved surface according to a circuit requirement; each strip structure has a size capable of installing the plurality of LED chips; the spherical curved surface and the circular curved surface have different quantities of parallel circuit areas connected in series, and the plurality of connecting portions are disposed across the isolation slot and bent into a V-shape to reduce the circumference and size of the conductive plate, so as to form a space structure of the conductive plate structure; each strip structure arranging with an interval apart in a direction from external diameter towards internal diameter comprises a bending portion, a fixing hole, an electrode slot, a fixing hole, a bending portion, and a plane of the fixed planar structure; two fixing holes form a group, and the group of the fixing holes, the plane, and the electrode slot are disposed between the aforementioned two bending portions; the support frame is designed as a hemispherical structure with a main body formed by a plurality of support ribs, and having different quantities of radially arranged support ribs disposed on the spherical curved surface and the circular curved surface respectively; each support rib matches the strip structure of the conductive plate; each support rib has a group of fixing columns, a support surface disposed between the group of fixing columns, and each support surface matching with each group of fixing columns may be passed through and combined with each group of fixing holes, so as to support and fix the fixed planar structure of the conductive plate; a ventilation hole is formed between the support ribs; an external circular surface of the support frame has a latch slot, and the external circular surface is attached to the circular curved surface of the conductive plate.

15. The LED illumination apparatus according to claim 14, being used as a bulb lamp, wherein the bulb lamp is formed by two identical conductive plates and two support frames, and each conductive plate is supported and fixed by a support frame; each support frame has a latch slot and a combining portion formed at the opening end of the external circular surface, so that two support frames can be embedded into one another closely, and the opening end of the external circular surface of each support frame has a sling hole provided for installing the sling and a power cord.

16. The LED illumination apparatus according to claim 9, being used as a long lamp tube, characterized in that the structure of the conductive plate comprises a power contact, a plurality of electrode slots, a plurality of connecting portions, a plurality of isolation slots, and a plurality of strip structures, wherein the conductive plate is cut by a plurality of isolation slots to form a plurality of parallel strip structures; the conductive plate further includes a U-shaped cross-sectional structure with two flap combining portions, and the U-shaped cross-section is formed by bending the plurality of bending portions to a relative distance, and each flap combining portion is formed by bending two bending portions at the edges; when the flap of the lamp cover is embedded into a latch slot of the support frame, the combining portion is engaged and fixed; each strip structure has a plurality of bending portions, a plurality of fixing holes, a plurality of electrode slots, and a plurality of planes of the fixed planar structure; wherein each plane and the electrode slot are disposed between two bending portions having different intervals and divided into two parts by one of the isolation slots, so that two adjacent strip structures are assembled into each plane and the electrode slot, and each electrode slot is mounted onto the isolation slot; a fixing hole is formed at an edge of the plurality of electrode slots of each strip structure; the two fixing holes of the two adjacent strip structures are disposed on both sides of each plane and combined to form a group; a body of the middle strip structure replaces the connecting portion to define a series connection between the LED chip parallel circuit areas; and the support frame is a rectangular structure with a U-shaped cross-section, and the plurality of transverse parallel support ribs are assembled into a strip structure; each support rib has a group of fixing columns, and a support surface disposed between the group of fixing columns, and each support surface matched with each group of fixing columns may be passed through and combined with each group of fixing holes to support and fix the fixed planar structure of the conductive plate; more than one ventilation holes are formed between the support ribs; the support frame has two outer side edges; each group of fixing columns are passed through and combined with each group of fixing holes respectively; and the outer side edge of the support frame has a latch slot and an inner latch slot.

17. The LED illumination apparatus according to claim 10, being used as a rectangular flat lamp, wherein the conductive plate comprises a power contact, a plurality of electrode slots, a plurality of connecting portions, a plurality of isolation slots, and a plurality of strip structures; the plurality of isolation slots arranged in a row direction or a column direction are cut open to form a plurality of parallel strip structures; the conductive plate is formed by a plurality of rectangular slots arranged in plural rows by plural columns, and the adjacent rectangular slots are connected with each other by their aslant edges, and the plane of the bottom has an electrode slot and each LED chip installed thereon, and its external periphery has a combining portion of the flap; and the row or column slot has a cross-section formed by bending the plurality of bending portions and the bending portions on two edges of the aslant surface along the row or column direction; each strip structure has a plurality of bending portions, a plurality of fixing holes, a plurality of electrode slots, and a plurality of planes of the fixed planar structure; each plane and the electrode slot ad disposed between two row and column bending portions with a different interval apart and divided into two parts by the isolation slot, and two adjacent strip structures are assembled to form the plane and the electrode slot, and each electrode slot is mounted onto the isolation slot; each strip structure has a plurality of electrode slots, and the edge of each connecting portion has a fixing hole; the fixing holes of the two adjacent strip structures are disposed on both sides of the plane and combined into a group; a body of the middle strip structure replaces the connecting portion to define a series connection between the LED chip parallel circuit areas; the support frame is in a rectangular shape having a plurality of rectangular slots arranged in rows and columns, and each rectangular slot has a strip support rib installed therein and matched with the plane of the rectangular slot of the conductive plate, and each strip support rib has a plurality of support surfaces and two fixing columns, and the two fixing columns may be passed through and combined with the fixing hole of the conductive plate to for support and fix the fixed planar structure; both sides of each support rib have two ventilation holes respectively; an external circular surface of the support frame has a latch slot, and the external circular surface of the support frame is attached to the combining portion of the conductive plate.

18. A manufacturing method of an LED illumination apparatus, comprising an unloading process, a mounting process, a reclaiming process, a formation preparation process, a bending process, an assembling process, and an auxiliary portion removing process; and the aforementioned processes further including the measure of an LED chip protection mechanism, so that an electrode soldering point of each LED chip is protected in each process, and deformation is reduced in the processes, wherein the unloading process stamps a metal sheet to form a material board, such that the material board comprises a plurality of strip structures separated by a plurality of isolation slots, and a plurality of auxiliary portions capable of causing a short circuit and disposed across a connecting portion of the isolation slot is provided for connecting the strip structure, and the material board is formed to be a plate structure; the mounting process mounts the LED chip onto the plurality of electrode slots of the material board by soldering; the reclaiming process cuts the plurality of connecting plates from the material board and removes a flat stamping board; the formation preparation process uses a stamping mold to press and position a positioning portion of the stamping board and pre-press the stamping board at a predetermined position to produce a bending deformation according to the required 3D space of the conductive plate, and the bending deformation includes the deformation of the bending portion and the deformation of the connecting portion; the bending process uses the stamping mold to press the fixed planar structure of the pre-deformed stamping board and bend the bending portion and forms a 3D space structure of the conductive plate by the stamping board; the assembling process assembles the support frame and combines and fixes the support frame into the interior of the conductive plate, and pass each fixing column of the support frame through each fixing hole of the conductive plate, such that each support surface attaches and supports the fixed planar structure of the conductive plate to provide the necessary structural support to the conductive plate in the follow-up process, and a ventilation hole formed between the support ribs of the support frame has an area capable of covering each cut auxiliary portion of the conductive plate; and the auxiliary portion removing process uses the stamping mold to press the fixed planar structure of the conductive plate and the support rib of the support frame and further to cut open each auxiliary portion of the conductive plate to prevent the electrode from being short circuited, so as to complete a series-parallel circuit.

19. The manufacturing method of an LED illumination apparatus according to claim 18, wherein the LED chip protection mechanism is installed and connected into the electrode slot by the plurality of auxiliary portions to form a single-component conductive plate, and forms the fixed planar structure between the fixing holes of the conductive plate, the periphery of the LED chip and its non-opening area, and each group of fixing holes of the conductive plate and each group of fixing columns of each support rib are combined with each other, and a support surface between each group of fixing columns attaches, presses and supports the fixed planar structure of the conductive plate, so that an electrode soldering point of each LED chip can be protected in each process.

20. The manufacturing method of an LED illumination apparatus according to claim 19, being applied for a flat bulb lamp, wherein the bending process bends the bending portion at the external diameter to form a shallow cup-shaped conductive plate with a circular surface and cut the positioning portion to form a center hole; the assembling process passes each fixing column of the support frame through the fixing hole of the conductive plate, and the support surface of each support rib matches with each fixing column passing through each fixing hole for attaching and supporting the fixed planar structure of the conductive plate, and an external circular surface of the support frame is attached to the bending portion of the conductive plate, and a fixing ring of the support frame is passed through the center hole of the positioning portion.

21. The manufacturing method of an LED illumination apparatus according to claim 19, being applied for a convexly curved surface bulb, wherein the bending process further comprises a pre-assembling bending process and a post-assembling bending process; the formation preparation process further uses the stamping mold to position the center hole of the positioning portion and presses the fixed planar structure closely and bends each connecting portion of the isolation slot disposed across the conductive plate into a V-shape, so as to bend each strip structure towards the backside, and reduces each strip structure near the bending portion along the circumferential direction, so that the width of each isolation slot is reduced further, and now the stamping board becomes a conical structure and each LED chip is situated on the outer side, and the external periphery of each LED chip is still maintained to be flat; the pre-assembling bending process further comprises a spherical curved surface bending process and a circular curved surface bending process, wherein the spherical curved surface bending process uses the stamping mold to press the positioning portion and the fixed planar structure into a predetermined conical angle, and then performs a spherical curved surface formation operation, and the width of the isolation slot at the external diameter is reduced further; the circular curved surface bending process cuts the positioning portion to form a circular center hole, and uses the stamping mold to press each fixed planar structure to perform a circular curved surface formation operation, and the stamping board so form is a conductive plate with a 3D space, and the spherical curved surface and the circular curved surface jointly form a hemispherical shape, and each connecting portion disposed across the isolation slot is further bent into a V-shape, and the width of the isolation slot of the conical curved surface and the cylindrical surface is also reduced; the assembling process further combines the support frame and the conductive plate, and the external circular surface is attached to the internal curved surface of the bending portion, and the support surface of each support rib is matched with each fixing column passing through each fixing hole to attach and support the fixed planar structure of the conductive plate, and the fixing ring is passed through the center hole of the positioning portion; the pre-assembling bending process is a conical curved surface and cylindrical surface bending process that uses the stamping mold to fix the support frame after cutting each auxiliary portion open and form the conical curved surface and the cylindrical surface of the conductive plate, and since the bending portion at the intersection of the conical curved surface has a plurality of bending holes to weaken the structural strength for an easy bending effect, so that the external circular surface of the support frame can be attached to the bending portion, so as to form the conical curved surface and the cylindrical surface.

22. The manufacturing method of an LED illumination apparatus according to claim 19, being applied for a concavely curved surface bulb, wherein the bending process further comprises a pre-assembling bending process and a post-assembling bending process; wherein the formation preparation process further uses the stamping mold to position the center hole of the positioning portion and press the fixed planar structure closely and bend each connecting portion of the isolation hole disposed across the conductive plate into a V-shape, and bend each strip structure towards the rear side, and bend each strip structure near the bending portion in the circumferential direction, so as to further reduce the width of each isolation slot, and further bend each connecting portion into a deep V-shape, and now, the stamping board becomes a conical structure, and each LED chip is disposed on the outer side, and now, the external periphery of each LED chip is maintained to be flat; the pre-assembling bending process further comprises a concave spherical surface bending process and a concave circular curved surface bending process, wherein the concave spherical surface bending process further uses the stamping mold to press the positioning portion and the fixed planar structure into a predetermined conical angle and then deform the concave spherical surface, and the concave spherical surface of the structure is still maintained to be a conical surface, and the bending portion of each strip structure is bent at the external diameter of the fixing hole, and the bending angle of the bending portion is greater than 90 degrees, so that the conical curved surface and the cylindrical surface are in form of a radial plane, and each LED chip is still disposed on the inner side, and the width of the isolation slot on the internal diameter of the concave circular curved surface is reduced, and the width of the isolation slot on the external diameter becomes larger due to the planar shape; the concave circular curved surface bending process cuts and removes the positioning portion to form a circular center hole, and the stamping mold is used again to press the fixed planar structure and form the concave circular curved surface, and the bending portion at the external diameter of the fixing hole of each strip structure is bent, so that the bending portion between the concave circular curved surface and the conical curved surface becomes an inverted U-shaped bending, and the U-shaped bending portion has a bending angle substantially equal to 180 degrees, and the stamping board so formed becomes the conductive plate with a 3D space, and the concave spherical surface and the concave circular curved surface form a concave hemispherical curved surface, and the conical curved surface and the cylindrical surface form an outwardly flapped cylinder, and the V-shaped connecting portion disposed across the isolation slot is further bent, and the width of the conical curved surface and the cylindrical surface is also reduced; the assembling process combines the support frame and the conductive plate and attaches an external circular surface of the support frame to an internal curved surface of the U-shaped bending portion, and the support surface of each support rib is matched to each fixing column passing through each fixing hole to attach and support the fixed planar structure of the conductive plate, and pass the latch slot of the support frame through the isolation slot, and the fixing ring is passed through the center hole; the post-assembling bending process is a conical curved surface and cylindrical surface bending process, and uses the stamping mold to fix the support frame after each auxiliary portion process ends stamping mold and also form the conical curved surface and the cylindrical surface of the conductive plate, and since the bending portions at two intersections of the conical curved surface have a plurality of bending holes to weaken the structural strength and make the bending process easy, and the external circular surface of the support frame is attached to the U-shaped bending portion of the conductive plate, so as to form the conical curved surface and the cylindrical surface.

23. The manufacturing method of an LED illumination apparatus according to claim 18, being applied for a hemispherical lamp, wherein the formation preparation process further uses the stamping mold to position the center hole of the positioning portion and presses the fixed planar structure closely and bends the connecting portion of the isolation slot disposed across the stamping board into a V-shape to weaken the strength of the connecting portion along the circumferential direction; the formation preparation process further uses the stamping mold to position the center hole of the positioning portion, and reduces the strip structure near the bending portion of a circular curved surface along the circumferential direction, so that the width of each isolation slot is further reduced, and each V-shaped connecting portion is further bent into a deep V-shape, so that the stamping board of the planar structure becomes a conical structure, wherein each strip structure in the circumferential direction has not been bent into a curved surface; the external periphery of each LED chip is maintained to be planar in this process; the bending process further uses the stamping mold to press the fixed planar structure of the spherical curved surface into a predetermined conical angle, and then bend two bending portions of the strip structure of the spherical curved surface, so that the circular curved surface becomes a conical surface; and then the positioning portion is cut and removed to form a circular center hole, and the stamping mold is used again to press the fixed planar structure of the circular curved surface and then bend the two bending portions of the strip structure, and the circular curved surface and the spherical curved surface jointly form the conduct plate with a hemispherical space structure, and the connecting portion disposed across each isolation slot is bent into a V-shape; when the assembling process combines the support frame and the conductive plate, the external circular surface of the support frame is attached to the circular curved surface of the conductive plate, and the support surface of each support rib is matched with and combined with each fixing column passing through each fixing hole to attach and support the fixed planar structure of the conductive plate.

24. The manufacturing method of an LED illumination apparatus according to claim 18, being applied for a long lamp tube, wherein the bending process uses a row of fixing holes on an outer side of a stamping board as the positioning portion and further uses the stamping mold to press the fixed planar structure of the column and bend the bending portions on both sides of the stamping board into an angle, so that the combining portion becomes an angle flap with an angle substantially equal to a right angle, and then the aforementioned process is repeated, and the stamping mold with a bending angle is used to fix the fixing holes at another column, and press the fixed planar structure, and bend the bending portion for several times, so that the stamping board forms a conductive plate structure with a U-shaped cross-section and having two flap combining portions; the assembling process combines the support frame and the conductive plate, and attaches the outer side edge to the combining portion, and the support surface of each support rib is matched and combined with each fixing column passing through each fixing hole to attach and support the fixed planar structure of the conductive plate.

25. The manufacturing method of an LED illumination apparatus according to claim 18, being applied for a rectangular flat lamp, further comprising a shaping process, wherein the bending process further uses the stamping mold to select a row direction or a column direction, and uses the fixing hole of the fixed planar structure in such direction as the positioning portion, and press the fixed planar structure in the row direction or the column direction and bend the bending portions on both sides of the stamping board with a large angle, so that the combining portion has an angled flap with an angle substantially equal to 150 degrees, and then the bending portion of the fixed planar structure is bent, and the same bending process is repeated in one direction and then in another direction until all bending portions at the fixed planar structure and the periphery of the rectangular slot are bent; so that the stamping board is formed into a conductive plate having a plurality of rectangular slot structures arranged in rows and columns; the shaping process shapes the rectangular slot and further uses the stamping mold to combine and position each fixing hole and presses a plane of the fixed planar structure closely and shapes the final dimensions of the rectangular slot and the aslant surface of its opening; the assembling process combines the support frame and the conductive plate, and the external circular surface of the support frame is attached to the combining portion of the conductive plate, and the support surface of each support rib is matched with each fixing column passing through each fixing hole to attach and support the fixed planar structure of the conductive plate.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0054] FIG. 1 is a perspective view of a flat bulb lamp of the present invention;

[0055] FIG. 1(a) is an exploded view of a flat bulb lamp of the present invention;

[0056] FIG. 1(b) is a cross-sectional view of a flat bulb lamp of the present invention;

[0057] FIG. 1(c) is a circuit diagram of a flat bulb lamp of the present invention;

[0058] FIG. 1(d) is a schematic view of a material board of a flat bulb lamp of the present invention;

[0059] FIG. 1(e) is a schematic view of a stamping board of a flat bulb lamp of the present invention;

[0060] FIG. 1(f) is a perspective view of a support frame of a flat bulb lamp of the present invention;

[0061] FIG. 1(g) is a semi-sectional perspective view of an illumination apparatus of a flat bulb lamp of the present invention;

[0062] FIG. 1(h) is a schematic view of removing an auxiliary portion of a conductive plate of a flat bulb lamp of the present invention;

[0063] FIG. 1(i) is a flow chart of a manufacturing method of an illumination apparatus of a flat bulb lamp of the present invention;

[0064] FIG. 2 is a perspective view of a convexly curved surface bulb of the present invention;

[0065] FIG. 2(a) is an exploded view of a convexly curved surface bulb of the present invention;

[0066] FIG. 2(b) is a sectional view of a convexly curved surface bulb of the present invention;

[0067] FIG. 2(c) is a schematic view of a material board of a convexly curved surface bulb of the present invention;

[0068] FIG. 2(d) is a schematic view of a stamping board of a convexly curved surface bulb of the present invention;

[0069] FIG. 2(e) is a perspective view of a support frame of a convexly curved surface bulb of the present invention;

[0070] FIG. 2(f) is a semi-sectional perspective view of an illumination apparatus of a convexly curved surface bulb lamp of the present invention;

[0071] FIG. 2(g) is a schematic view of bending and forming a spherical curved surface of a conductive plate of a convexly curved surface bulb lamp of the present invention;

[0072] FIG. 2(h) is a schematic view of removing an auxiliary portion of a conductive plate of a convexly curved surface bulb lamp of the present invention;

[0073] FIG. 2(i) is a flow chart of a manufacturing method of an illumination apparatus of a convexly curved surface bulb of the present invention;

[0074] FIG. 3 is a perspective sectional view of a concavely curved surface bulb of the present invention;

[0075] FIG. 3(a) is an exploded view of a concavely curved surface bulb of the present invention;

[0076] FIG. 3(b) is a sectional view of a concavely curved surface bulb of the present invention;

[0077] FIG. 3(c) is a perspective view of a support frame of a concavely curved surface bulb of the present invention;

[0078] FIG. 3(d) is a schematic view of bending and forming a conductive plate of a concavely curved surface bulb of the present invention;

[0079] FIG. 3(e) is a schematic view of bending and forming a concave circular curved surface of a conductive plate of a concavely curved surface bulb of the present invention;

[0080] FIG. 3(f) is a schematic view of removing an auxiliary portion of an illumination apparatus of a concavely curved surface bulb lamp of the present invention;

[0081] FIG. 4 is a perspective semi-sectional view of a hemispherical lamp of the present invention;

[0082] FIG. 4(a) is an exploded view of a hemispherical lamp of the present invention;

[0083] FIG. 4(b) is a sectional view of a hemispherical lamp of the present invention;

[0084] FIG. 4(c) is a circuit diagram of a hemispherical lamp of the present invention;

[0085] FIG. 4(d) is a schematic view of a material board of a hemispherical lamp of the present invention;

[0086] FIG. 4(e) is a schematic view of a stamping board of a hemispherical lamp of the present invention;

[0087] FIG. 4(f) is a perspective view of a support frame of a hemispherical lamp of the present invention;

[0088] FIG. 4(g) is a schematic view of an illumination apparatus of a hemispherical lamp of the present invention;

[0089] FIG. 5 is a perspective view of a bulb lamp of the present invention;

[0090] FIG. 5(a) is an exploded view of a bulb lamp of the present invention;

[0091] FIG. 5(b) is a sectional view of a bulb lamp of the present invention;

[0092] FIG. 6 is a perspective view of a strip lamp of the present invention;

[0093] FIG. 6(a) is a perspective semi-sectional view of a strip lamp of the present invention;

[0094] FIG. 6(b) is a circuit diagram of a strip lamp of the present invention;

[0095] FIG. 6(c) is a perspective view of a support frame of a strip lamp of the present invention;

[0096] FIG. 6(d) is a schematic view of an illumination apparatus of a strip lamp of the present invention;

[0097] FIG. 6(e) is a partial perspective sectional view of an illumination apparatus of a strip lamp of the present invention;

[0098] FIG. 7 is a perspective view of a rectangular planar lamp of the present invention;

[0099] FIG. 7(a) is an exploded view of a rectangular planar lamp of the present invention;

[0100] FIG. 7(b) is a sectional view of a rectangular planar lamp of the present invention;

[0101] FIG. 7(c) is a schematic view of a material board of a rectangular planar lamp of the present invention;

[0102] FIG. 7(d) is a schematic view of a stamping board of a rectangular planar lamp of the present invention;

[0103] FIG. 7 (e) shows the external appearance of a support frame of a rectangular planar lamp of the present invention;

[0104] FIG. 7(f) is a sectional view of a rectangular planar lamp of the present invention;

[0105] FIG. 7(g) is a schematic view of forming a longitudinal combining portion of a conductive plate of a rectangular planar lamp of the present invention;

[0106] FIG. 7(h) is a schematic view of forming a longitudinal bending portion of a rectangular planar lamp of the present invention;

[0107] FIG. 7(i) is a schematic view of forming a transverse combining portion of a rectangular planar lamp of the present invention;

[0108] FIG. 7(j) is a schematic view of forming a complete conductive plate of a rectangular planar lamp of the present invention; and

[0109] FIG. 7(K) is a flow chart of a manufacturing method of an illumination apparatus of a rectangular planar lamp of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0110] The aforementioned and other objectives and advantages of this disclosure will become clearer in light of the following detailed description of an illustrative embodiment of this invention described in connection with the drawings.

[0111] The present invention relates to an LED illumination apparatus and a manufacturing method thereof, and seven embodiments of the present invention and seven system diagrams are provided for illustrating the core technology of the present invention, wherein FIGS. 11(i) illustrate an illumination apparatus and its manufacturing method of a flat bulb lamp in accordance with the first embodiment of the present invention, FIGS. 22(h) illustrates an illumination apparatus of a curved surface in accordance with the second embodiment of the present invention, so on. It is noteworthy that the main components with the same function are represented by their respective numerals respectively in each embodiment of the present invention to simplify the description of the present invention.

[0112] With reference to FIG. 1(e) for an illumination apparatus of the first embodiment of the present invention, the illumination apparatus comprises a conductive plate 2 and a support frame 3 combined with each other; wherein the conductive plate 2 is cut into a plurality of strip structures 20 from a plurality of isolation slots 21 by a stamping board 80, and a plurality of connecting portions 23 is disposed across each isolation slot 21 and combined to form a planar sheet structure (if each electrode slot 22 is disposed at the isolation slot 21, then each auxiliary portion 221 will be disposed across the electrode slot 22 and the isolation slot 21 simultaneously), and each auxiliary portion 221 causes a short circuit which is marked by slant sectional lines for the purpose of recognition.

[0113] With reference to FIG. 1(g) for an illumination apparatus in accordance with an embodiment of the present invention, the illumination apparatus comprises an electrode soldering point protection mechanism of an LED chip 11 which is a fixed planar structure 29 formed between by each group of fixing holes 27 of the conductive plate 2, the periphery of the LED chip 11 and its non-opening area, and each group of fixing holes 27 of the conductive plate 2 and each group of fixing columns 33 of the support frame 3 are combined with each other, and each support surface 301 disposed between the fixing column 33 is attached to the fixed planar structure 28 for supporting the fixed planar structure 28. It is noteworthy that the fixed planar structure 28 may be a circular strip structure, a concentric circular strip structure, a U-shaped strip arranged structure, or a rectangular arranged structure according to the configuration of each LED chip 11.

[0114] Both sides of the electrode slot 22 are divided into a low potential electrode 222 and a high potential electrode 223 respectively. Wherein, the plurality of fixing holes 27 are disposed on both sides of the electrode slot 22, and each group of fixing holes 27 is combined with a group of fixing columns 33 of the support rib 30 for protecting the electrode soldering point of the LED chip 11. In addition, each fixing column 33 is passed and extended to each fixing hole 27 for its connection, so as to fix the fixing column 33 to the corresponsive fixing hole 27 by the deformation of each fixing column 33 or by using an adhesive.

[0115] With reference to FIGS. 1(g) and 1(h) for an embodiment of the present invention, a support surface 301 of a support rib 30 of the support frame 3 may be attached to the fixed planar structure 28, of the conductive plate 2 for pressing a stamping mold; a ventilation hole 34 is formed between the support ribs 30, and the area of each ventilation hole 34 covers an auxiliary portion 221 to be cut, so that each auxiliary portion 221 is pressed by the stamping mold and cut open.

[0116] With reference to FIG. 1(c) for an illumination circuit 1, 10, 100 of different embodiments of the present invention, the illumination circuit 1, 10, 100 comprises a circuit 101, a circuit 102, a circuit 103, a circuit 104, a circuit 105, and a circuit 106. In addition, the conductive plate 2 configured to be corresponsive to a three-series-three-parallel circuit 1 mainly using 3 LED chips 11 for a parallel circuit area 12 (in other words, three strip structures 20 are connected to form the parallel circuit area 12), and there are three parallel circuit areas 12. In addition, at least two connecting portions formed between the parallel circuit areas 12 are used for connecting the parallel circuit areas 12 in series to form the three-series-three-parallel illumination circuit 1.

[0117] With reference to FIG. 1(d) for the illumination circuit 1, the power contacts of the illumination circuit 1 are divided into a positive power contact 13 and a negative power contact 14, and the connecting portion 23 in the parallel circuit is further divided into a parallel connecting portion 23a1, a parallel connecting portion 23a2, a parallel connecting portion 23b1, a parallel connecting portion 23b2, a parallel connecting portion 23c1, a parallel connecting portion 23c2, and the connecting portion 23 in the serial circuit is further divided into a serial connecting portion 23s1 and a serial connecting portion 23s2.

[0118] With reference to FIG. 1(e), the parallel connecting portion 23a1 connected to a positive power contact 13 corresponsive of the corresponsive circuit 101 as shown in FIG. 1(d) is connected to a high potential contact of the LED chip 11 of the first group, and the parallel connecting portion 23a2 (corresponsive to the circuit 102) is connected to a low potential contact of the LED chip 11 in parallel, and the serial connecting portion 23s1 is connected to the parallel connecting portion 23a2 and the parallel connecting portion 23b1 (corresponsive to the circuit 103); and the parallel connecting portion 23b1 is connected to a high potential contact of the second group of LED chips in parallel, and the parallel connecting portion 23b2 (corresponsive to the circuit 104) is connected to a low potential contact of the second group of LED chips, and the serial connecting portion 23s2 is connected to the parallel connecting portion 23b2 and the parallel connecting portion 23c1 (corresponsive to the circuit 105); and the parallel connecting portion 23c1 is connected to a high potential contact of the third group of LED chips 11 in parallel, and the parallel connecting portion 23c2 (corresponsive to the circuit 106) is connected to a low potential contact of the third group of LED chips 11c in parallel and combined with a positive power contact 14. The seven embodiments of the present invention are described below:

[0119] With reference to FIG. 11(b) for a flat bulb lamp A with a planar light emission function in accordance with the first embodiment of the present invention, an illumination apparatus is comprised of a support frame 3 and a conductive plate 2, wherein the flat bulb lamp A comprises a lamp cover 6, an aluminum alloy radiating base 4, a connector 5, a conductive plate 2, a plurality of LED chips 11, a support frame 3, and a power module 51.

[0120] With reference to FIGS. 11(b) for the flat bulb lamp A installed in the ceiling, the connector 5 is disposed at the uppermost position; wherein, the lamp cover 6 is disposed at the lowermost position, and the lamp cover 6 is installed and combined to an end opening 43 of the radiating base 4 and has a plurality of ventilation holes 61 to constitute the external appearance of the flat bulb lamp A.

[0121] The power module 51 is installed in the radiating base 4 and has a power cord connected to a power contact of the conductive plate 2, and a connector 5 for supplying power to the LED chip 11.

[0122] The radiating base 4 is a conical pipe structure and has a plurality of heat dissipating fins 41 disposed at the external periphery of the radiating base 4, and a plurality of ventilation holes 42 are formed between the heat dissipating fins 41, and a heat conduction surface 44 and an external circular surface 40 are situated on both sides of the opening 43 respectively. When the heat generated by each LED chip 11 is conducted to the conductive plate 2, the heat is cooled by air convection and through the large-area heat conduction surface 26 of the conductive plate 2 and the conduction surface 44 of the radiating base 4, and the remained heat is transferred to the heat dissipating fins 41 of the radiating base 4 to facilitate heat dissipation.

[0123] With reference to FIGS. 1(e) and 1(g), a conductive plate 2 having a circular surface with a shallow cup-shaped structure is installed in the lamp cover 6, and each isolation slot 21 is divided to form nine radial strip structures 20, and each connecting portion 23 is disposed across and connected to the isolation slot 21 to form the illumination circuit of this embodiment. Each strip structure 20 comprises a plurality of fixing holes 27 distributed on both sides of an electrode slot 22, and a bending portion 24 disposed on the external periphery such that after the conductive plate 2 is bent into a circular shape, a heat conduction surface 26 is formed, and the heat conduction surface 26 is connected to the heat conduction surface 44 of the radiating base 4 as shown in FIG. 1(b) and attached to an external circular surface 32 of the support frame 3.

[0124] With reference to FIG. 1(f), the support frame 3 corresponsive to the conductive plate 2 is a circular disc structure with the external circular surface 32, and the support frame 3 matched with the conductive plate 2 is formed by nine radially arranged strip support ribs 30, and each support rib 30 has a group of fixing columns 33, and a support surface 301 is formed between the two fixing columns 30, and each support surface 301 is provided for attaching and supporting the fixed planar structure 28 of the conductive plate 2; and a ventilation hole 34 is formed between each support rib 30 to produce a circumferential arrangement, and each group of fixing columns 33 is passed through and combined with the fixing hole 27 of the conductive plate 2, and the external circular surface 32 of the support frame 3 is attached to the bending portion 24 of the conductive plate 2, and the support frame 3 is combined and fixed to a position of the opening 43 of the radiating base. It is noteworthy that each fixing hole 27 of the conductive plate 2, the fixed planar structure 28 of the circular strip structure, and the support rib 30, the support surface 301, and each fixing column 33 of the support frame 3 form the electrode soldering point protection mechanism of the LED chip of the illumination apparatus of this embodiment, and the manufacturing method 9a of an illumination apparatus of this embodiment also adopts the measure of the electrode soldering point protection mechanism of the LED chip.

[0125] With reference to FIG. 1(c)1(e) for the schematic views of a series-parallel circuit of a flat bulb lamp A and a stamping board 80 (which is the conductive plate 2 before formation) of the present invention, three strip structures 20 form a parallel circuit area 12, and then the serial connecting portion 23s1 and the serial connecting portion 23s2 are arranged and disposed across the isolation slot 21 to connect the plurality of parallel circuit areas 12 in series, so as to form the three-series-three-parallel illumination circuit 1 of this embodiment.

[0126] With reference to FIG. 1(i) for a manufacturing method 9a of an illumination apparatus a of the present invention, the method comprises an unloading process, a mounting process, a reclaiming process, a formation preparation process, a bending process, an assembling process and an auxiliary portion removing process.

[0127] With reference to FIGS. 1(d) and 1(e) for the unloading process, a material board 8 is processed through a stamping process, so that the material board 8 has the feature of an external appearance with a stamping board 80, a plurality of connecting plates 82, a plurality of positioning holes 81 and a plurality of cut holes 83.

[0128] In the mounting process, each LED chip 11 is soldered onto the plurality of electrode slots 22 of the stamping board 80.

[0129] In the reclaiming process, the plurality of connecting plates 82 are cut from the material board 8 and a stamping board 80 is removed.

[0130] In the formation preparation process, a stamping mold is provided to press the positioning portion 25 of the stamping board 80 and the fixed planar structure 28 closely.

[0131] In the bending process, the stamping board 80 bends the bending portion 24 to form a 3D conductive plate 2 as shown in FIG. 1(a).

[0132] In the assembling process as shown in FIG. 1(g), the support frame 3 and the conductive plate 2 are combined, and the external circular surface 32 and the bending portion 24 are attached to the heat conduction surface 26, and each fixing column 33 is passed through and combined with each fixing hole 27, and the support surface 301 of each support rib 30 supports and fixes the fixed planar structure 28 of the circular strip, and the fixing ring 31 of the support frame 3 is passed through the center hole of the positioning portion 25 for providing the support of the conductive plate 2 in the follow-up operations and completing the electrode soldering point protection mechanism, of the LED chip to facilitate the follow-up processes.

[0133] With reference to FIG. 1(h) for the auxiliary portion removing process, a stamping mold is provided for pressing the support frame 3 and the conductive plate 2 and cutting open each auxiliary portion 221, so that the position of the short-circuit auxiliary portion 221 becomes the electrode slot 22, so as to form the complete three-series-three-parallel illumination circuit 1 of this embodiment as shown in FIG. 1(c).

[0134] With reference to FIG. 22(b) for a convexly curved surface bulb B having a light emission function on a convex curved surface in accordance with the second embodiment of the present invention, an illumination apparatus b is comprised of a support frame 3 and a conductive plate 2, and the illumination circuit 1 of the aforementioned first embodiment is adopted. Wherein, the convexly curved surface bulb B comprises a lamp cover 6, a protective cover 7, a connector 5, a conductive plate 2, a plurality of LED chips 11, a support frame 3, and a power module 51.

[0135] The illumination apparatus B of this embodiment installed in the ceiling has a connector 5 disposed at the uppermost position, and the lamp cover 6 is disposed at the lowermost position. The lamp cover 6 is connected to the support frame 3 disposed at the position of an end opening of the protective cover 7 and the other end of the protective cover 7 is connected to the connector 5 to form the external appearance of the convexly curved surface bulb B of this embodiment.

[0136] The lamp cover 6 is a hemispherical opening structure installed outside the illumination apparatus b and made of a transparent or semi-transparent material, and the lamp cover 6 has a plurality of ventilation holes 61, and the lamp cover 6 is embedded into the latch slot 35 and other through holes of the support frame 3 for the fixation and combination purpose as shown in FIG. 2(b).

[0137] The protective cover 7 is a long curved conical tubular structure installed outside the illumination apparatus b and has a fixing slot 71 and a plurality of ventilation holes 73 formed thereon, wherein the cylindrical surface 244 of the conductive plate 2 is fixed to the fixing slot 71 as shown in FIG. 2(b).

[0138] The power module 51 is installed in the conductive plate 2 and fixed into the protective cover 7, and the power module 51 has a power cord connected to the conductive plate 2 and the connector 5 for supplying the required power to the LED chip 11 of the present invention as shown in FIG. 2 (b).

[0139] With reference to FIGS. 2(a), 2(b) and 2(f), the conductive plate 2 has a 3D curved surface, and the support frame 3 is provided for supporting and fixing the conductive plate 2, and the conductive plate 2 is divided by each isolation slot 21 to form a circumferentially arranged strip structure 20, and an end of the conductive plate 2 is a hemispherical curved surface formed by a spherical curved surface 241 and a circular curved surface 242, and the other end of the conductive plate 2 is in a conical shape formed by a conical curved surface 243 and a cylindrical surface 244.

[0140] With reference to FIG. 2(d) for a structure of the conductive plate 2, the structure comprises a power contact, a plurality of electrode slots 22, a positioning portion 25, a plurality of connecting portions 23, a plurality of isolation slots 21, and a plurality of strip structures 20. Each isolation slot 21 is extended radially outward to divide the conductive plate 2 into nine strip structures 20 distributed at equal angles and disposed around the periphery of the center hole of the positioning portion 25. The connecting portion 23 disposed across the isolation slot 21 is bent by the stamping mold into a V-shape to reduce the circumference, so as to form a 3D curved surface structure of the conductive plate 2 to meet the series-parallel connection requirement of the illumination circuit 1.

[0141] With reference to FIG. 2(g), each strip structure 20 arranging in a direction from the cylindrical surface 244 towards the spherical curved surface 241 comprises a bending portion 24a disposed between the cylindrical surface 244 and the conical curved surface 243, a bending portion 24b disposed between the circular curved surface 242 and the conical curved surface 243, a bending portion 24c disposed on the spherical curved surface 241; a plurality of fixing holes 27b disposed on the spherical curved surface 241, a plurality of fixing holes 27a disposed on the circular curved surface 242, wherein the two fixing holes 27a, 27b form a group; the electrode slot 22 is formed between the spherical curved surface 241 and the circular curved surface 242 and disposed at the middle of each group of fixing holes 27.

[0142] With reference to FIG. 2(e), the support frame 3 is an opening hemispherical structure formed by nine radially arranged support ribs 30, and each support rib 30 has a group of fixing columns 33a, 33 b, a support surface 301 formed between the group of fixing columns 33a, 33 b, and each support surface 301 is provided for attaching and supporting the fixed planar structure 28 of the conductive plate 2; two ventilation holes 34 are formed between each support rib 30; a fixing ring 31 is disposed at the middle of the support frame 3, and a plurality of external circular surfaces 32 are formed at the external circumference of the support frame 3; the fixing ring 31 is passed through the center hole of the positioning portion 25 of the conductive plate 2; each external circular surface 32 has a plurality of latch slots 35 formed thereon and provided for combining the lamp cover 6 and the protective cover 7. It is noteworthy that each fixing hole 27a, 27b and the fixed planar structure 28 of the conductive plate 2 and the support rib 30, the support surface 301, and each fixing column 33a, 33b of the support frame 3 form an electrode soldering point protection mechanism of the LED chip with a circular strip structure of an illumination apparatus b of this embodiment, and the manufacturing method 9b of an illumination apparatus b of this embodiment also has the measure of the soldering point protection mechanism of the LED chip electrode.

[0143] With reference to FIGS. 1(c) and 2(c) for the illumination circuit 1 of the illumination apparatus b, and the illumination circuit 1 is a three-series-three-parallel illumination circuit 1, the relation with the structure of the conductive plate 2 of this embodiment is illustrated. Each strip structure 20 has an LED chip 11 and uses three strip structures 20 and the LED chip 11 to form a parallel circuit area 12, and there are three groups of parallel circuit areas 12, and the two connecting portions 23s1, 23s2 connect each parallel circuit area 12 in series to form the illumination circuit 1.

[0144] With reference to FIG. 2(i) for a manufacturing method 9b of an illumination apparatus b of this embodiment, the manufacturing method 9b comprises an unloading process, a mounting process, a reclaiming process, a formation preparation process, a pre-assembling bending process, an assembling process, an auxiliary portion removing process and a post-assembling bending process. It is noteworthy that this embodiment and the following embodiments have the same unloading process, mounting process, and reclaiming process of the stamping board 80 as those of the first embodiment, and thus they will not be repeated.

[0145] With reference to FIGS. 2(i), and 2(f)2(h) for the process of bending and forming the conductive plate 2 by the stamping board 80, the stamping mold 80 is used in the formation preparation process as shown in FIG. 2(g) to position the center hole of the positioning portion 25 and press the circular strip fixed planar structure 28 and bend each connecting portion 23 disposed across the isolation slot 21 on the stamping board 80 into a V-shape to weaken the strength of each connecting portion 23 along the circumferential direction, and then reduce the strip structure near the bending portion 24c along the circumferential direction, so that the width of each isolation slot 21 is further reduced, and the V-shaped connecting portion 23 is bent further into a deep V-shape, and the stamping board 80 of the planar structure is a conical structure as shown in FIG. 2(g). Wherein, each strip structure 20 at the outermost periphery in the circumferential direction is not bent into a curved surface, and the circular strip fixed planar structure 28 of this process can still be maintain to be planar to protect the electrode soldering point of the LED chip, so as to minimize the deformation.

[0146] The pre-assembling bending process further comprises a spherical curved surface bending process and a circular curved surface bending process. With reference to FIG. 2(g) for the spherical curved surface bending process, a stamping mold is provided for pressing the circular strip fixed planar structure 28 to a predetermined conical angle to bend the bending portion 24c to form a spherical curved surface 241, so that the circular curved surface 242, the conical curved surface 243, and the cylindrical surface 244 form a conical surface, and the width of each isolation slot 21 disposed on the external diameter is reduced significantly. With reference to FIG. 2(h) for the circular curved surface bending process, the positioning portion 25 is cut and removed to form a circular center hole, and then the stamping mold is used to press and fix each fixed planar structure 28 again, and each bending portion 24b is bent to form the circular curved surface 242, the spherical curved surface 241 and the circular curved surface 242 to form a hemispherical shape. Now, the width of the isolation slot 21 disposed at the external diameter is reduced.

[0147] With reference to FIG. 2(h) for the assembling process, the support frame 3 and the conductive plate 2 (which is the stamping board 80) are combined, and its external circular surface 32 is attached to the bending portion 24b of the conductive plate 3 for providing the support for the follow-up operations and complete the electrode soldering point protection mechanism of the LED chip.

[0148] In the auxiliary portion removing process, the stamping mold is provided for pressing the support frame 3 and the conductive plate 2 and then cutting open each auxiliary portion 221, so that the position of the original short-circuit auxiliary portion 221 has become the electrode slot 22.

[0149] The post-assembling bending process further comprises a conical curved surface bending process and a cylindrical surface bending process. With reference to FIG. 2(f), the stamping mold is finally used for fixing the support frame 3 to bend the bending portion 24a and the bending portion 24b of the conductive plate 2. Due to the bending hole 261, the structural strength is weakened, so that the conical curved surface 243 and the cylindrical surface 244 can be formed to complete the three-series-three-parallel illumination circuit 1 of this embodiment.

[0150] With reference to FIG. 33(b) for a concavely curved surface bulb C having a light emission function at a concavely curved surface in accordance with the third embodiment of the present invention, an illumination apparatus c of this embodiment is comprised of a support frame 3 and a conductive plate 2, wherein the concavely curved surface bulb C comprises a lamp cover 6, a protective cover 7, a connector 5, a conductive plate 2, a plurality of LED chips 11, a support frame 3, and a power module 51. It is noteworthy that this embodiment adopts the aforementioned illumination circuit 1, the lamp cover of the first embodiment, and the protective cover and the power module 51 of the second embodiment.

[0151] With reference to FIGS. 3(a) and 3(b) for a concavely curved surface bulb C installed in the ceiling, a connector 5 is disposed at the uppermost position, and the lamp cover 6 is disposed at the lowermost position. In addition, the lamp cover 6 and an end opening of the protective cover 7 are connected to a latch slot 35 of the support frame 3, and the other end of the protective cover 7 is connected to the connector 5 to form the external appearance of the concavely curved surface bulb C.

[0152] With reference to FIG. 3(f) for a stamping board 80 of a conductive plate 2 of this embodiment which is similar to the aforementioned second embodiment, the formation process forms a convex curved surface by the spherical curved surface 241 and the circular curved surface 242 of the aforementioned second embodiment which is bent into concave hemispherical curved surface formed by a concave spherical surface 241a and a concave circular curved surface 242a. In the formation operation of the concave circular curved surface 242a, the bending portion 24b is bent in a reverse direction into a U-shape.

[0153] The conductive plate 2 of this embodiment is installed in the lamp cover 6 and the protective cover 7, and the conductive plate 2 is supported and fixed into the support frame 3. In addition, the conductive plate 2 is divided by each isolation slot 21 into circumferentially arranged strip structure 20 and distributed at the periphery of the positioning portion 25. In addition, an end of the conductive plate 2 is a concave hemispherical curved surface formed by the concave spherical surface 241a and the concave circular curved surface 242a, and the other end of the conductive plate 2 is in a conical shape formed by the conical curved surface 243 and the cylindrical surface 244, and the bending portion 24b is bent into a U-shape, and then the cylindrical surface 244 of the conductive plate 3 is fixed into the fixing slot 71 of the protective cover 7.

[0154] With reference to FIG. 3(a) for the structure of the conductive plate 2, the conductive plate 2 comprises a power contact, a positioning portion 25, a plurality of connecting portions 23, a plurality of isolation slots 21, and a plurality of strip structures 20. Each connecting portion 23 disposed across the isolation slot 21 is bent by the stamping mold into a V-shape to reduce the circumference to form the 3D structure. With reference to FIGS. 3(d) and 3(e), each strip structure 20 arranging in a direction from the cylindrical surface 244 towards the concave spherical surface 241a comprises a bending portion 24a disposed between the cylindrical surface 244 and the conical curved surface 243, a bending portion 24b disposed between the concave circular curved surface 242a and the conical curved surface 243, a bending portion 24c disposed on the concave spherical surface 241a; a plurality of fixing holes 27b disposed on the concave spherical surface 241a, and another fixing hole 27a disposed on the concave circular curved surface 242a, and the two fixing holes 27a, 27b form a group; each electrode slot 22 is formed between the concave spherical surface 241a and the concave circular curved surface 242a and disposed between each group of fixing holes 27.

[0155] With reference to FIGS. 3 and 3(c), the support frame 3 is an opening concave hemispherical structure installed in the conductive plate 2 having a 3D curved surface and formed by a plurality of radially arranged support ribs 30, and each support rib 30 has fixing columns 33a, 33b which are group into two, and more than one ventilation hole 34 are formed between each support rib 30; the center of the support frame 3 has a fixing ring 31 and the external circumference of the support frame 3 has an external circular surface 32; each group of fixing columns 33a, 33b are passed through and combined with each group of fixing holes 27a, 27b of the conductive plate 2, and the fixing ring 31 is passed through the center hole of the positioning portion 25 of the conductive plate 2; the external circular surface 32 of the support frame 3 is disposed on an opening end and capable of attaching the bending portion 24b of the conductive plate 2, and the latch slot 35 is provided for fixing the lamp cover 6 and the protective cover 7. The power module 51 is installed in the protective cover 7 and a power cord is connected to the conductive plate 2 and the connector 5. It is noteworthy that each fixing hole 27a, 27b of the conductive plate 2, the fixed planar structure 28 of the circular strip, and the support rib 30, the support surface 301 and each fixing column 33a, 33b of the support frame 3 form the electrode soldering point protection mechanism of the LED chip of the illumination apparatus c of this embodiment, and the manufacturing method 9 of an illumination apparatus of the following embodiment also has the LED chip electrode soldering point protection mechanism.

[0156] With reference to FIG. 2(i) for a manufacturing method of an illumination apparatus c of this embodiment, the manufacturing method comprises an unloading process, a mounting process, a reclaiming process, a formation preparation process, a pre-assembling bending process, an assembling process, an auxiliary portion removing process and a post-assembling bending process.

[0157] In the formation preparation process as shown in FIG. 2(d), a stamping mold is provided for positioning the center hole of the positioning portion 25 to press the circular strip fixed planar structure 28 and bend the connecting portion 23 of a serial circuit disposed across the isolation slot 21 into a V-shape to weaken the strength of the connecting portion 23 along the circumferential direction. With reference to FIG. 3(d), the strip structure 20 near the bending portion 24b is reduced along the circumferential direction to further reduce the width of each isolation slot 21, and each V-shaped connecting portion 23 is bent further into a deep V-shape. In other words, the stamping board 80 (which is the conductive plate 2) with a planar structure is a conical structure. Now, each LED chip 11 is installed on an inner side, wherein each strip structure 20 along the circumferential direction is not bent into a curved surface yet. In this process, the fixed planar structure 28 of the circular strip still maintains to be planar to protect the electrode soldering point of the LED chip 11, so as to minimize the deformation, since most deformations usually occur at the connecting portion 23 and the isolation slot 21 with a reduced width.

[0158] With reference to FIGS. 3(c), 3(d) and 3(e) for the pre-assembling bending process, the pre-assembling bending process further comprises a concave spherical surface bending process and a concave circular curved surface bending process, wherein the concave spherical surface bending process uses a stamping mold to press and fix the positioning portion 25 and the circular strip fixed planar structure 28 at a predetermined conical angle, and then the bending portion 24c is bent into the concave spherical surface 241a, and the concave circular curved surface 242a, the conical curved surface 243, and the cylindrical surface 244 form a conical surface. Now, the width of the isolation slot 21 disposed at the external diameter is reduced significantly.

[0159] With reference to FIG. 3(e), the concave circular curved surface bending process uses the stamping mold to press and fix the positioning portion 25 and the circular strip fixed planar structure 28 and bend the bending portion 24b, so that the conical curved surface 243 and the cylindrical surface 244 form a radial plane, and each LED chip 11 is still disposed on the inner side, and the width of the isolation slot 21 disposed on the concave circular curved surface 242a is reduced, and the width of each isolation slot 21 disposed on the external diameter is relatively larger due to the planar shape. And then, the positioning portion 25 is cut and removed to form the circular center hole, and the stamping mold is used again to press and fix the circular strip fixed planar structure 28 and bend the bending portion 24b, so that the concave circular curved surface 242a is formed. In other words, the concave spherical surface 241a and the concave circular curved surface 242a jointly form a concave hemispherical curved surface.

[0160] With reference to FIG. 3(e), the bending portion 24b is bent, and a inverted U-shape is formed between the concave circular curved surface 242a and the conical curved surface 243, and the conical curved surface 243 and the cylindrical surface 244 form an outwardly flapped cylindrical shape, and the V-shaped connecting portion 23 disposed across the isolation slot 21 is further bent, and the width of the isolation slot 21 on the conical curved surface 243 and the cylindrical surface 244 is reduced.

[0161] In the assembling process as shown in FIG. 3(e), the support frame 3 and the conductive plate 2 are combined, and the external circular surface 32 is attached to an inner curved surface of the U-shaped bending portion 24b for providing the support of the conductive plate 2 in the follow-up operations, and completing the electrode soldering point protection mechanism of the LED chip 11 to facilitate the follow-up processes.

[0162] With reference to FIG. 3(e) for the auxiliary portion removing process, the stamping mold is used for pressing the support frame 3 and the conductive plate 2 and cutting open each auxiliary portion 221, and the position of the original short-circuit auxiliary portion 221 becomes the electrode slot 22.

[0163] The post-assembling bending process further comprises a conical curved surface bending process and a cylindrical surface bending process. With reference to FIG. 3(f), the stamping mold is provided for fixing the support frame 3 and forming a conical curved surface 243 and a cylindrical surface 244 of the conductive plate 2. Since the bending portion 24b and the bending portion 24a have a bending hole (not shown in the figure), the structural strength is weakened, and the stamping mold can bend the bending portions easily, and the external circular surface 32 of the support frame 3 is attached to the U-shaped bending portion 24b to provide the required support for the following bending operation, and form the conical curved surface 243 and the cylindrical surface 244, so as to complete the three-series-three-parallel illumination circuit 1 of this embodiment.

[0164] With reference to FIGS. 44(c) for a hemispherical lamp D of the fourth embodiment of the present invention, an illumination apparatus is comprised of a support frame 3 and a conductive plate 2, and the illumination circuit 10 is comprised of three groups of three-series-three-parallel circuits, and there are a total of 27 LED chips 11. In addition, the illumination apparatus d of the hemispherical lamp comprises a lamp cover 6, a protective cover 7, a conductive plate 2, a plurality of LED chips 11, a support frame 3, and a power module 51.

[0165] When the hemispherical lamp D is installed, the protective cover 7 id disposed at the uppermost position, and the lamp cover 6 is disposed at the lowermost position. Both of the lamp cover 6 and the protective cover 7 are installed into a latch slot 35 of the support frame 3 simultaneously as shown in FIG. 4(b), so as to form the structure of the hemispherical lamp D.

[0166] The lamp cover 6 is a hemispherical opening structure made of a transparent or semi-transparent material, and the lamp cover 6 has the latch ring 62 and a plurality of ventilation holes 61. The protective cover 7 is a shallow circular opening structure having the latch ring 72 and a plurality of ventilation holes 73, wherein the aforementioned two latch rings 62, 72 are latched into the latch slot 35 of the support frame 3.

[0167] The power module 51 installed in the protective cover 7, and a power cord of the power module 51 is electrically coupled to the conductive plate 2 for supplying the required power to each LED chip 11 of the present invention.

[0168] With reference to FIG. 4(g), the conductive plate 2 is installed in an internal space formed by the lamp cover 6 and the protective cover 7, and the conductive plate 2 is supported and fixed by the support frame 3, and the conductive plate 2 has an end with a hemispherical curved surface formed by a spherical curved surface 241 and a circular curved surface 242.

[0169] With reference to FIG. 4(f), the support frame 3 is a semi-opening hemispherical structure installed in the conductive plate 2 and has 9 radially arranged support ribs 30 disposed opposite to the spherical curved surface 241, and 18 radially arranged support ribs 30 disposed on the circular curved surface 242, and each support rib 30 has a group of fixing columns 33; and at least one ventilation hole 34 is formed between two adjacent support ribs 30; and a fixing ring 31 is installed at the middle of the support frame 3, and an external circular surface 32 is formed around the external periphery of the support frame 3, and the external circular surface 32 has the latch slot 35; each group of fixing columns 33 are passed through each group of fixing holes 27 of the conductive plate 2, so that the fixing ring 31 is sheathed by the center hole of the positioning portion 25 of the conductive plate 2.

[0170] With reference to FIG. 4(c) for the illumination circuit 10 of the hemispherical lamp D and FIG. 4(d) for the circuit of the stamping board 80, the spherical curved surface 241 has a group of 3-series-3-parallel-connection illumination circuits, and the circular curved surface 242 has two groups of 3-series-3-parallel-connection illumination circuits.

[0171] With reference to FIGS. 4(d) and 4(e), the stamping board 80 is divided by 9 radial isolation slots 21 into 9 radially arranged strip structures 20, and a circular isolation slot 21a disposed between the spherical curved surface 241 and the circular curved surface 242 isolates and divides each strip structure 20. In other words, each strip structure 20 is divided by the isolation slot 21a into two parts, respectively: a strip structure 20a and a strip structure 20b, and the circular isolation slot 21a has a plurality of auxiliary portions 221 to assure a complete structure capable of connecting the strip structure 20a and the strip structure 20b, and a connecting portion 23 is disposed across the isolation slot 21a, and a parallel high potential circuit is used as a positive power contact 13.

[0172] With reference to FIG. 4(e), the spherical curved surface 241 and the circular curved surface 242 have a circular electrode slot 22, so that each strip structure 20a may install a plurality of LED chips 11; every three strip structures 20a form a parallel circuit area 12, and there are a total of three parallel circuit areas 12, and these parallel circuit area 12 are connected into a three-parallel-three-series connection, and there are 9 LED chips installed on the spherical curved surface 241 of the illumination circuit.

[0173] With reference to FIG. 4(e), radial isolation slot 21b is added to the middle of every three circumferentially arranged strip structures 20b on the circular curved surface 242 and divided into two strip structures 20c; the strip structure 20c has an LED chip 11, and two LED chips 11 are installed on the non-divided strip structure 20b, and one strip structure 20c and one strip structure 20b have a total of 3 LED chips 11 which form a parallel circuit area 12, so that a series connection is defined in the three parallel circuit areas 12, so as to form a three-series-three-parallel circuits with a total of 9 LED chips 11, and the circular curved surface 242 has two groups of three-series-three-parallel circuits with a total of 18 LED chips 11.

[0174] It is noteworthy that each fixing hole 27 and the concentric circular strip fixed planar structure 28 of the conductive plate 2 and the support rib 30, the support surface 301, and each fixing column 33 of the support frame 3 form an LED chip electrode soldering point protection mechanism of the illumination apparatus d of this embodiment, and the manufacturing method 9b of the illumination apparatus d of this embodiment also comprises the LED chip electrode soldering point protection mechanism.

[0175] With reference to FIGS. 4, 4(d), and 4(e) for the manufacturing method of the illumination apparatus d of this embodiment, the manufacturing method of this embodiment is substantially the same as that of the aforementioned second embodiment. Referring to FIG. 2(i) as well, the manufacturing method of the illumination apparatus d of this embodiment comprises an unloading process, a mounting process, a reclaiming process, a formation preparation process, a pre-assembling bending process, an assembling process, an auxiliary portion removing process and a post-assembling bending process.

[0176] In the bending process, a stamping mold is provided to press and fix a concentric circular strip fixed planar structure 28 of the spherical curved surface 241 to a predetermined conical angle, and then bending the two bending portions 24c, 24b of the strip structure 20a to form a spherical curved surface 241, so that the circular curved surface 242 forms a conical surface, and the width of the isolation slot 21 on the external diameter is reduced significantly; and then the positioning portion 25 is cut and removed to form a circular center hole, and the stamping mold is used again to press the concentric circular strip fixed planar structure 28 of the circular curved surface 242 and bend the bending portion 24b and the bending portion 24 of the strip structure 20b and the strip structure 20c respectively to form the circular curved surface 242. Now, the stamping board 80 becomes the structure of the conductive plate 2. In addition, the spherical curved surface 241 and the circular curved surface 242 jointly form a hemispherical shape, and each connecting portion 23 disposed across the isolation slot 21 is bent into a V-shape and has a very small width, and the width of the isolation slot 21 and the isolation slot 21a is reduced to a predetermined width.

[0177] With reference to FIG. 4(g) for the assembling process, the support frame 3 and the conductive plate 2 are combined, and each support rib 30 of the support frame 3 is connected to the interior of the conductive plate 2, and the fixing ring 31 of the support frame 3 is sheathed onto the positioning portion 25 of the conductive plate 2 for supporting the conductive plate 2 in the follow-up operation and completing the electrode soldering point protection mechanism of the LED chip.

[0178] In the auxiliary portion removing process, the stamping mold is used to press the support frame 3 and the conductive plate 2 and cut open each auxiliary portion 221, so that these auxiliary portions 221 become electrode slots 22, so as to form the illumination circuits 10 with three groups of three-parallel-three-series connections in accordance with this embodiment.

[0179] The bulb lamp E in accordance with the fifth embodiment of the present invention is an extension of the fourth embodiment of the present invention, the bulb lamp E adopts the same series-parallel illumination circuit 10 with two groups of conductive plates and lamp covers of the fourth embodiment, and the support frame structure of the fourth embodiment is changed to a support frame 3, 3a of this embodiment.

[0180] In FIGS. 55(b), the bulb lamp E is formed by left and right lamp covers 6, two conductive plates 2, a plurality of LED chips 11, two support frames 3, 3a, and a power module 51, and the two support frames 3, 3a and the lamp cover 6 are embedded and integrated to form the bulb lamp E.

[0181] When the bulb lamp E is installed, a sling and a power cord 37 disposed at the uppermost position are passed through a sling hole 321 formed on an external circular surface 32 of the support frame 3, so that the external circular surface 32 is situated at a vertical status, and the two lamp covers 6 are disposed on both sides respectively. In FIG. 5, the two lamp covers 6a are installed onto a combining portion 36a of the two support frames 3, 3a, and the support frame 3 is embedded and integrated by another combining portion 36 to form the external appearance of the bulb lamp E of this embodiment.

[0182] Each conductive plate 2 is disposed in each lamp cover 6, and each conductive plate 2 is installed in the support frame 3 to provide support and fixation, and has a shape of a hemispherical curved surface formed by a spherical curved surface 241 and a circular curved surface 242.

[0183] With reference to FIG. 5(a), the difference between the two support frames 3, 3a of this embodiment and the support frames of the fourth embodiment resides on the opening end of the external circular surface 32 of this embodiment has a combining portion 36, 36a to combine and embed the two support frames 3, 3a closely with each other, and the opening end of the external circular surface 32 further has at least one sling hole 321 for installing a sling and a power cord 37. It is noteworthy that the illumination apparatus of this embodiment also has the electrode soldering point protection mechanism of the LED chip of the concentric circular strip structure of the aforementioned embodiment.

[0184] With reference to FIG. 66(b) for an LED illumination apparatus of the sixth embodiment of the present invention, the LED illumination apparatus is a long lamp tube F using the illumination circuit 10 which is a rectangular circuit in compliance with the requirement of the long lamp tube F, and the illumination apparatus f of this embodiment is comprised of a support frame 3 and a conductive plate 2. Wherein, the long lamp tube F comprises a lamp cover 6, a protective cover 7, two connectors 5, a plurality of conductive plates 2, a plurality of LED chips 11, a plurality of support frames 3, and a power module 51.

[0185] The long lamp tube F of this embodiment is installed to a lamp holder at the ceiling, and the protective cover 7 is disposed at the uppermost position, and the lamp cover 6 is disposed at the lowermost position, and the connector 5 is installed on both sides of the lamp tube individually. In addition, the lamp cover 6 and the protective cover 7 are installed to a latch slot 35 and an inner latch slot 35a of the support frame 3 as shown in FIG. 6(a), and the protective cover 7 and the support frame 3 are fixed to the connectors 5 on both sides of the lamp, and the connector 5 has a power pin 52, so as to constitute the external appearance of the long lamp tube F.

[0186] With reference to FIG. 6(a), the lamp cover 6 is a strip opening structure with a U-shaped cross-section, and both lateral sides of the lamp cover 6 have a flap 63, the lamp cover 6 is made of a transparent or semi-transparent material, and the lamp cover 6 has a plurality of ventilation holes 61 formed thereon, and the flap 63 is embedded into the latch slot 35. The protective cover 7 is a rectangular plate structure installed to the inner latch slot 35a of the support frame 3 and has a ventilation hole 73 formed thereon.

[0187] Further, the power module is installed and fixed into the protective cover 7 and has a power cord connected to the conductive plate 2 and two connectors 5. Each connector 5 is provided for combining the support frame 3, and the power pin 52 is connected to the power module and the power supply of the lamp holder for supplying the required power to each LED chip 11.

[0188] The conductive plate 2 is disposed in the lamp cover 6 and supported and fixed by the support frame 3. The conductive plate 2 is divided by the isolation slot 21 into four parallelly arranged strip structures 20 and has two flap combining portions 262 with a U-shaped cross-sectional structure; and flap 63 of the lamp cover 6 is embedded into the latch slot 35 of the support frame 3.

[0189] With reference to FIG. 6(d), the conductive plate 2 comprises a power contact, a positioning portion (which is a fixing hole 27a, 27b), a plurality of connecting portions 23, a plurality of isolation slots 21, and a plurality of strip structures 20. Each strip structure 20 has four bending portions 24a-24d, two bending portions 24e, 24f, and three fixing holes 27a, 27b, three electrode slots 22 with an auxiliary portion 221; and each electrode slot 22 is disposed between two bending portions with an unequal interval apart, and a high potential electrode and a low potential electrode are disposed on both edges of the isolation slot 21 respectively, and the three fixing holes 27a or 27b are formed at the edges of the electrode slot 22; the U-shaped cross-section is formed by bending four bending portions 24a-24d in a relative distance, and the flap combining portion 262 is formed by bending the two bending portions 24e, 24f.

[0190] Further, the isolation slot 21 between every two adjacent strip structures 20 has three electrode slots 22 and a total of three parallel circuit areas 12. Both edges of each electrode slot 22 have a fixing hole 27a, 27b each, wherein a fixing hole 27a is formed on a strip structure 20, and another fixing hole 27b is formed on another strip structure 20, and the two fixing holes 27a, 27b form a group; a body of two strip structures 20 arranged at the middle replaces the serial connecting portion 23s1 and the serial connecting portion 23s2 of the illumination circuit 10 to define a series connection between the parallel circuit areas 12 of the LED chip, and the illumination circuit 10 with the three-parallel-three-series connection has a total of 9 LED chips.

[0191] With reference to FIG. 6(c), the support frame 3 is a rectangular structure with a U-shaped cross-section and formed by plural groups of support ribs 30 and the support ribs 30 are transversely and parallelly arranged and disposed on the support frame 3, and every three support ribs 30 match with of a strip structure 20 of the conductive plate 3, wherein each support rib 30 has a group of fixing columns 33a, 33b and a support surface 301 formed between the fixing columns 33a, 33b, and each support surface 301 is provided for attaching a U-shaped strip fixed planar structure 28 of the conductive plate 2; a plurality of ventilation holes 34 is formed between each support rib 30; each group of fixing columns 33a, 33b are passed through and combined with each group of fixing holes 27a, 27b of the conductive plate 2; two outer side edges 320 of the support frame 3 have a latch slot 35 and an inner latch slot 35a respectively for fixing and combining the lamp cover 6 and the protective cover 7; the ventilation hole 34 of the support frame 3 is provided for cooling airflow which is advantageous for cutting open and removing the auxiliary portion 221. It is noteworthy that each fixing hole 27a, 27b and the U-shaped strip fixed planar structure 28 of the conductive plate 2, and the support rib 30, the support surface 301, and each fixing column 33a, 33b of the support frame 3 jointly form an electrode soldering point protection mechanism of the LED chip of the illumination apparatus f of this embodiment. The manufacturing method 9a of the illumination apparatus f of this embodiment also comprises the LED chip electrode soldering point protection mechanism.

[0192] With reference to FIGS. 6(b) and 6(d) for the three-parallel-three-series illumination circuit 100 formed by the conductive plate 2, the conductive plate 2 is divided by three isolation slots 21 to form four parallel longitudinally arranged strip structures 20 from the stamping board 80. The isolation slot 21 between every two parallel strip structures 20 has three electrode slots 22 for installing 3 LED chips 11 onto a parallel circuit area 12, and a total of three parallel circuit areas 12 are formed, and a body of the two middle strip structures 20 replaces the serial connecting portion 23s1 and the serial connecting portion 23s2 of the illumination circuit 100 to define the series connection between the parallel circuit areas 12, so as to form the three-parallel-three-series illumination circuit 100 with a total of 9 LED chips.

[0193] With reference to FIGS. 6 and 6(a) for a long lamp tube, the lamp is an illumination apparatus of a fluorescent lamp formed by connecting the aforementioned three-series-three-parallel circuit units of the plurality of illumination apparatuses fin series.

[0194] The manufacturing method of the illumination apparatus f of this embodiment is similar to that of the first embodiment as shown in FIG. 1(i), the manufacturing method comprises an unloading process, a mounting process, a reclaiming process, a formation preparation process, a bending process, an assembling process, and an auxiliary portion removing process.

[0195] In the bending process as shown in FIGS. 6(c)6(d), a stamping mold is provided for positioning the longitudinal fixing holes 27a, 27b disposed closest to the edge, pressing the fixed planar structure 28 closely and bending the bending portion 24e, 24f on both edges of the stamping board into an angle, so that the two flap combining portions 262 become right-angled flaps, and then the following processes are repeated: the stamping mold is used to position each fixing hole 27a, 27b of the longitudinal bending portion 24a to be bent, and then the adjacent fixed planar structures 28 are pressed to bent the longitudinal bending portions 24b, 24c, 24d for several times in a linear longitudinal direction, so that the conductive plate 2 forms a U-shaped cross-sectional structure having two flap combining portions 262. In this process, the external periphery of each LED chip 11 is maintained to be a flat area to protect the electrode soldering point of the LED chip 11.

[0196] In the assembling process, the support frame 3 and the conductive plate 2 are combined with each other, and the two outer side edges 320 of the support frame 3 are attached to the two flap combining portions 262 of the conductive plate 3 to provide the support of the conductive plate 2 in the follow-up operations and complete the electrode soldering point protection mechanism of the LED chip 11.

[0197] In the auxiliary portion removing process, the stamping mold is used to press the support frame 3 and the conductive plate 2 and cut open each auxiliary portion 221, and the position of the original short-circuit auxiliary portion 221 has become the electrode slot 22, so as to form a complete three-series-three-parallel illumination circuit 100 of this embodiment.

[0198] With reference to FIGS. 77(b) for a rectangular flat lamp G in accordance with the seventh embodiment of the present invention, this embodiment is an extension of the aforementioned sixth embodiment and also relates to the three-parallel-three-series illumination circuit 100, and an illumination apparatus g of the rectangular flat lamp G of this embodiment comprises a support frame 3 and a conductive plate 2. In this embodiment, the material board 8 and its stamping board 80 as shown in FIGS. 7(c) and 7(d) come with a structure having two mutually perpendicular mesh structures bent in two mutually perpendicular directions. Wherein, the rectangular flat lamp G comprises a lamp cover 6, a protective cover 7, a conductive plate 2, a plurality of LED chips 11, a support frame 3, and a power module 51. When the rectangular flat lamp G of this embodiment is installed to the ceiling, the protective cover 7 is disposed at the uppermost position and installed to the ceiling, and the lamp cover 6 is disposed at the lowermost position, and its internal power contact is connected to an external power supply. The lamp cover 6 and the protective cover 7 are fixed and combined with the latch slot 35 of the support frame 3 to constitute the external appearance of rectangular flat lamp G of this embodiment.

[0199] The lamp cover 6 is a rectangular opening structure made of a transparent or semi-transparent material and has a plurality of ventilation holes 61 formed thereon. In addition, the lamp cover 6 is embedded and combined into the latch slot 35 of the support frame 3 in order to position the flap combining portion 262 of the conductive plate 2. In addition, the opening aslant surface 245 of the rectangular slot of the conductive plate 2 is provided for reflecting the light of each LED chip 11 to the outside.

[0200] The power module 51 is installed in the protective cover 7 and fixed to the protective cover 6, and the power module 51 has a power cord for connecting a power contact of the conductive plate to supply the required power to each LED chip 11.

[0201] With reference to FIG. 7(j), the conductive plate 2 is supported and fixed by the support frame 3, and the conductive plate 2 is formed by three-by-three nine rectangular slots, and two adjacent rectangular slots and their aslant surfaces 245 are connected to each other, and a rectangular fixed planar structure 28 disposed at the bottom of each rectangular slot has an electrode slot 22 and an LED chip 11, so that each electrode slot 22 and each LED chip 11 are also arranged in a rectangular shape, and the fixed planar structure 28 is enclosed by the groups of four aslant surfaces 245. Further, the external circular surface around the conductive plate 2 has a flap combining portion 262, and its rectangular slots arranged in rows and columns are formed by bending the four bending portions 24 along the row and column directions.

[0202] Further, the conductive plate 2 as shown in FIGS. 7(d) and 7(j), the three isolation slots 21 arranged in the row and column directions are cut open to form four strip structures 20, and the three strip structures 20 in row and column divide each plane of the fixed planar structure 28 into two parts. In other words, each plane is disposed on two adjacent strip structures 20, and each isolation slot 21 has a plurality of electrode slots 22, and there are 3 LED chips 11 connected in parallel to form a parallel circuit area 12. In this embodiment, three are three parallel circuit areas 12; and both side edges of each electrode slot 22 have a fixing hole 27; and a body of two middle strip structures 20 replaces the serial connecting portion 23s1 and the serial connecting portion 23s2 of the illumination circuit 100 as shown in FIG. 6(b) to define a series connection between the parallel circuit areas 12.

[0203] The support frame 3 as shown in FIG. 7(e) is installed in the conductive plate 2 and in a rectangular shape matched with the strip structure 20 of the conductive plate 2, and the support frame 3 has three-by-three nine rectangular slots, and a strip support rib 30 is disposed at the bottom of each rectangular slot, and both sides of the support rib 30 have a ventilation hole 34 each; and each strip support rib 30 has a support surface 301, and the support surface 301 has a group of fixing columns 33, and the group of fixing columns 33 may be passed through and combined with a group of fixing holes 27 of the conductive plate 2, and the external circular surface 32 around the support frame 3 has the latch slot 35 provided for fixing the lamp cover 6 and the protective cover 7.

[0204] It is noteworthy that each fixing hole 27 and the rectangular fixed planar structure 28 of the conductive plate 2 and the support rib 30, the support surface 301, and each fixing column 33 of the support frame 3 jointly form an electrode soldering point protection mechanism of the LED chip of the illumination apparatus g of this embodiment. The manufacturing method 9g of the illumination apparatus f of this embodiment also has the electrode soldering point protection mechanism of the LED chip.

[0205] With reference to FIG. 7(K) for the manufacturing method 9g of the illumination apparatus g of this embodiment, the manufacturing method 9g comprises an unloading process, a mounting process, a reclaiming process, a formation preparation process, a bending process, a shaping process, an assembling process, and an auxiliary portion removing process.

[0206] In the bending process as shown in FIGS. 7(d) and 7(g), when the stamping mold selects a row direction or a column direction, the fixing hole 27 of the fixed planar structure 28 in the selected direction is used for positioning and pressing the fixed planar structure 28 in the row direction or the column direction and bending the bending portions 24 on both sides of the stamping board 80 into a large angle, so that the flap combining portion 262 becomes an obtuse flap, and then the bending portion 24 of the fixed planar structure 28 is bent. In FIG. 7(h), the same bending process is repeated in the same direction until the bending and forming process in the same row direction or the same column direction is completed. In FIG. 7(i), the bending in a different direction takes place, and the fixing hole 27 of the fixed planar structure 28 in such direction is used for positioning, and the same bending process is repeated until the bending process in the same row or column direction is completed as shown in FIG. 7(j). In other words, the aforementioned bending process is repeated until the four sides of each plane of the fixed planar structure 28 and the bending portions 24 on four aslant surfaces 245 of the rectangular slot are bent.

[0207] With reference to FIG. 7(j) for the shaping process, the shaping process of the rectangular slot takes place after the bending process ends, wherein a stamping mold is used to combine and fix all fixing holes 27 and press the fixed planar structures 28 arranged in a rectangular shape closely to size the final dimensions of each rectangular slot and shape the aslant surface 245 of the opening, so that the light of each LED chip 11 can be reflected to the outside.

[0208] With reference to FIG. 7(f) for the assembling process, the support frame 3 and the conductive plate 2 are combined with each other, and the external circular surface 32 of the support frame is attached to the flap combining portion 262 of the conductive plate to provide support to the conductive plate 2 for the follow-up operation and complete the electrode soldering point protection mechanism of the LED chip 11, so as to facilitate the follow-up process.

[0209] In the auxiliary portion removing process, the stamping mold is used to press the support frame 3 and the conductive plate 2 and cut open each auxiliary portion 221, and the position of the original short-circuit auxiliary portion 221 becomes the electrode slot 22, so as to form the illumination circuit of this embodiment.

[0210] In summation of the aforementioned embodiments, the present invention relates to an LED illumination apparatus and its manufacturing method, wherein a metal sheet is stamped to form a conductive plate with a 3D space, and the conductive plate has an illumination circuit, and a support frame is installed in the conductive plate, and the support frame is provided for supporting and fixing the conductive plate to facilitate the formation of the conductive plate and the protection of each LED chip soldering point, and the core components of an LED illumination apparatus of the present invention go with a lamp cover, a protective cover, and a power module exclusively designed for the LED illumination apparatus, so that various types of lamps with a better heat dissipating effect can be achieved, and the ventilation holes formed on the lamp cover and the protective cover have a slit width<1 mm for indoor protection (IP grade) such as IP40 grade, so that outside air is in direct contact with both sides of the conductive plate of the present invention to achieve the effect of convection and provide an excellent heat dissipating efficiency.