LED straight tube lamp

Abstract

The application provides an LED straight tube lamp, comprising: a lamp tube, the lamp tube comprising a diffusion coating covering the inner circumferential surface of the lamp tube; a lamp cap arranged at one end of the lamp tube; a lamp plate arranged in the lamp tube, the lamp plate being provided with a light source; a power supply, the power supply being in electrical communication with the light source through the lamp plate, the power supply comprising a circuit board and a power supply module arranged on the circuit board; the lamp plate is a flexible circuit board or a flexible substrate, the lamp plate having a part fixed on the inner circumferential surface of the lamp tube and a part located at both ends of the lamp plate and not fixed on the inner circumferential surface of the lamp tube, wherein the part not fixed on the inner circumferential surface of the lamp tube forms a free part, one end of the free part is deformed by being contracted towards the inside of the lamp tube, and the free part is directly welded to the circuit board of the power supply, the free part being an integral part of the flexible circuit board or the flexible substrate.

Description

[0001] This invention application is a divisional application filed with the Chinese Patent Office on September 25, 2015, with application number 201510622794.X and invention title "Rectifier Filter Circuit and LED Straight Tube Lamp". Technical Field

[0002] This invention relates to the field of lighting fixtures, specifically to an LED straight tube lamp and its light source design, electronic components, and lamp holder structure. Background Technology

[0003] LED lighting technology is rapidly developing and replacing traditional incandescent and fluorescent lamps. Unlike fluorescent lamps filled with inert gas and mercury, LED tube lights do not require mercury. Therefore, in various home and workplace lighting systems dominated by options such as traditional fluorescent bulbs and tubes, LED tube lights are unsurprisingly becoming a highly anticipated lighting option. The advantages of LED tube lights include improved durability and lifespan, as well as lower energy consumption. Therefore, considering all factors, LED tube lights are a cost-effective lighting option.

[0004] A typical LED straight tube light includes a tube, a circuit board containing the light source inside the tube, and lamp holders at both ends of the tube. The lamp holders contain a power supply, and the light source and power supply are electrically connected via the circuit board. However, existing LED straight tube lights still have the following quality problems that need to be addressed:

[0005] First, circuit boards are generally rigid boards. When the light tube breaks, especially when it breaks in a part, the entire LED straight tube light is still in a straight tube state. Users may mistakenly believe that the light tube can still be used and try to install it themselves, which can easily lead to leakage and electric shock accidents.

[0006] Secondly, in existing LED straight tube lights, the rigid circuit board and the lamp holder are generally electrically connected by metal wires through a bonding process. During the manufacturing, transportation, and use of LED straight tube lights, the metal wires are easily damaged or even broken due to handling, rendering the LED straight tube lights unusable. Moreover, the use of metal wire connections makes it difficult to achieve automated production in industrial applications.

[0007] Fourth, in existing LED tube lights, a grainy visual effect frequently occurs. The multiple LED chips arranged on the circuit board inside the tube are point light sources. Due to their point light source characteristics, without proper optical processing, the illumination throughout the tube is generally uneven. Therefore, for the observer of an LED tube light, the entire tube presents a grainy or uneven lighting effect, affecting visual comfort and even narrowing the viewing angle of the emitted light. In other words, the quality and aesthetic requirements of general consumers cannot be met. To address this problem, Chinese patent application CN 201320748271.6 discloses placing a diffuser tube inside a glass tube to reduce the grainy visual effect. However, the diffuser tube adds an interface to the light propagation path, increasing the probability of total internal reflection during propagation and reducing light output efficiency. Furthermore, the light absorption and rotation properties of the diffuser tube will also lead to a decrease in light output efficiency.

[0008] In view of the above problems, the present invention and its embodiments are presented below. Summary of the Invention

[0009] This abstract describes many embodiments of the "invention". However, the term "invention" is used only to describe certain embodiments disclosed in this specification (whether or not they are mentioned in the claims), and not a complete description of all possible embodiments. Some embodiments of the various features or aspects of the "invention" described below may be combined in different ways to form an LED tube light or a portion thereof.

[0010] The present invention provides a novel LED straight tube light, and its various aspects (and features) to solve the above-mentioned problems.

[0011] This invention provides an LED straight tube light, characterized in that it includes:

[0012] A lamp tube, the lamp tube including a diffusion coating covering the inner circumferential surface of the lamp tube, the lamp tube being a glass lamp tube;

[0013] Two lamp holders are respectively located at both ends of the lamp tube. Each lamp holder has holes for heat dissipation and a hollow conductive needle. The two lamp holders are the same size.

[0014] A lamp panel, disposed inside the lamp tube, is provided with a light source; and

[0015] A power supply, which is electrically connected to the light source through the lamp board, the power supply including a circuit board and a power module disposed on the circuit board;

[0016] The lamp board is a flexible circuit board or a flexible substrate. The lamp board has a portion fixed to the inner circumferential surface of the lamp tube and portions located at both ends of the lamp board that are not fixed to the inner circumferential surface of the lamp tube. The portions not fixed to the inner circumferential surface of the lamp tube form free portions. One end of the free portion contracts and deforms into the lamp tube, and the free portion is directly soldered to the circuit board of the power supply. The free portion is an integral part of the flexible circuit board or flexible substrate.

[0017] The lamp board described in this embodiment of the invention includes a conductive circuit layer, and the light source is disposed on the circuit layer and electrically connected to the power supply through the circuit layer.

[0018] In this embodiment of the invention, the length of the lamp panel is greater than the length of the lamp tube.

[0019] The circuit board described in this embodiment of the invention is a rigid circuit board to support the power module.

[0020] In this embodiment of the invention, the power module and the lamp board are located on opposite sides of the circuit board, and the power module is electrically connected through the circuit layer of the circuit board and the lamp board.

[0021] In this embodiment of the invention, the power module and the lamp board are both located on the same side surface of the circuit board, and the power module is directly electrically connected to the lamp board.

[0022] In this embodiment of the invention, the power supply is located in the lamp holder at one end of the lamp tube.

[0023] The power supply described in this embodiment of the invention has a power pad, and the end of the lamp board is provided with a light source pad, wherein the power pad and the light source pad are soldered together.

[0024] In this embodiment of the invention, the light source pad and the plane containing the light source on the lamp board are oriented in the same direction.

[0025] The light source pads in this embodiment of the invention have three, while the number of power supply pads is the same as the number of light source pads.

[0026] In this embodiment of the invention, the light source pads are arranged in a row.

[0027] The circuit board material described in this embodiment of the invention is harder than the material of the lamp board.

[0028] The lamp holder described in this embodiment of the invention is a metal lamp holder, and an insulator is provided at the lower part of the hollow conductive needle.

[0029] The diffusion coating described in this embodiment of the invention comprises any one of calcium carbonate, calcium halophosphate, and alumina, or a combination of any two of them, or a combination of all three.

[0030] The diffusion coating described in this embodiment of the invention comprises calcium carbonate and strontium phosphate.

[0031] This invention provides an LED straight tube light, characterized in that it includes:

[0032] A lamp tube, the lamp tube including a diffusion coating covering the inner circumferential surface of the lamp tube, the lamp tube being a glass lamp tube;

[0033] Two lamp holders are respectively located at both ends of the lamp tube. Each lamp holder has holes for heat dissipation and a hollow conductive needle. The two lamp holders are the same size and can be made of plastic or metal.

[0034] A lamp panel, disposed inside the lamp tube, is provided with a light source; and

[0035] A power supply, which is electrically connected to the light source through the lamp board, the power supply including a circuit board and a power module disposed on the circuit board;

[0036] The lamp board is a flexible circuit board or a flexible substrate. The lamp board has a portion fixed to the inner circumferential surface of the lamp tube and portions located at both ends of the lamp board that are not fixed to the inner circumferential surface of the lamp tube. The portions not fixed to the inner circumferential surface of the lamp tube form a free portion. One end of the free portion contracts and deforms into the lamp tube, and the free portion is directly soldered to the circuit board of the power supply. The free portion is an integral part of the flexible circuit board or flexible substrate.

[0037] The length of the lamp board is greater than the length of the lamp tube; the power supply has a power pad, and the end of the lamp board is provided with a light source pad, the power pad and the light source pad are soldered together; the light source pad and the plane on the lamp board where the light source is located face the same direction; the number of power pads is the same as the number of light source pads.

[0038] The diffusion coating described in this embodiment of the invention comprises calcium carbonate.

[0039] The diffusion coating described in this embodiment of the invention comprises calcium carbonate and strontium phosphate.

[0040] Compared with the prior art, the technical solution of the present invention has the following advantages:

[0041] Furthermore, the design of the heat dissipation holes in the lamp holder can solve the power supply heat dissipation problem and enhance the product's aesthetic appearance.

[0042] Furthermore, a diffusion coating is provided inside the lamp tube. When light passes through the diffusion coating, it can be diffused, correcting the light into a uniform surface light source to achieve an optical diffusion effect, ultimately resulting in a uniform distribution of brightness from the lamp tube. By setting a diffusion coating on the inner wall of the lamp tube, the graininess of the image can be reduced when the user is observing it, improving visual comfort; and the thickness of the diffusion coating can be very small, thereby maximizing the light output efficiency.

[0043] Furthermore, by directly attaching the light source to the inner circumference of the lamp tube, the lamp tube angle can be increased and the heat dissipation efficiency can be improved.

[0044] The lamp board uses a flexible circuit board, which prevents the lamp tube from remaining straight after it breaks, such as when it breaks into two pieces. This prevents users from thinking the lamp tube is still usable and attempting to install it themselves, thus avoiding electric shock accidents.

[0045] Furthermore, a free portion is formed at each end of the flexible circuit board along the axial direction of the lamp tube. The free portion bends and deforms into the lamp tube, which can improve the convenience of assembly and manufacturing.

[0046] Furthermore, the flexible circuit board is directly soldered to the power output terminal of the lamp holder, making it less prone to breakage during handling. Attached Figure Description

[0047] Figure 1 This is a perspective view of an LED straight tube lamp according to an embodiment of the present invention;

[0048] Figure 1A This is a perspective view of an LED straight tube lamp according to another embodiment of the present invention, showing that the lamp heads at both ends of the tube have different sizes;

[0049] Figure 2 This is an exploded perspective view of an LED straight tube lamp according to an embodiment of the present invention;

[0050] Figure 3 The external structure of the lamp holder of an LED straight tube lamp according to an embodiment of the present invention is shown;

[0051] Figure 4 The internal structure of the lamp holder of an LED straight tube lamp according to an embodiment of the present invention is shown;

[0052] Figure 5 This is a partial cross-sectional view of an LED straight tube lamp according to an embodiment of the present invention, showing the structure of the connection position between the lamp holder and the lamp tube;

[0053] Figure 6 This is a perspective sectional view of the lamp head of an LED straight tube lamp according to another embodiment of the present invention, showing that the lamp head is an all-plastic lamp head (containing a magnetic metal part and hot melt adhesive);

[0054] Figure 7This is a schematic diagram illustrating another embodiment of the LED straight tube lamp of the present invention, wherein the all-plastic lamp holder (containing a magnetic metal part and hot melt adhesive) and the lamp tube are heated and cured through an induction coil;

[0055] Figure 8 This is a three-dimensional structural diagram of an LED straight tube lamp according to another embodiment of the present invention, wherein the inner circumferential surface of the insulating tube of the all-plastic lamp holder has a support portion and a protrusion.

[0056] Figure 9 yes Figure 8 A cross-sectional view of the all-plastic lamp holder along the XX direction;

[0057] Figure 10 This is a schematic diagram showing a magnetically conductive metal component having at least one hollow structure when viewed in the radial direction.

[0058] Figure 11 This is a schematic diagram showing a magnetically conductive metal part having at least one indentation structure when viewed in the radial direction.

[0059] Figure 12 yes Figure 8 A cross-sectional view along the axial direction of the lamp tube after the insulating tube of the lamp holder is combined with the lamp tube, wherein the magnetic conductive metal part is a circular ring structure.

[0060] Figure 13 It is a cross-sectional view along the axial direction of the lamp tube, showing that the magnetic conductive metal part of the lamp head is an elliptical ring structure.

[0061] Figure 14 The lamp holder structure of an LED straight tube lamp according to another embodiment of the present invention is shown;

[0062] Figure 15 The end structure of the lamp tube in the LED straight tube lamp of various embodiments of the present invention is shown;

[0063] Figure 16 It is a sectional view, showing Figure 15 The structure of the transition section of the central lamp tube;

[0064] Figure 17 This is a cross-sectional view of the lamp tube in the LED straight tube lamp of the present invention along the axial direction, showing that the reflective film extends along the circumference of the lamp tube on both sides of the lamp plate;

[0065] Figure 18 It shows Figure 17 A cross-sectional view along the axial direction of the first modified example of the LED straight tube lamp, wherein the reflective film extends only along the circumference of the lamp tube on one side of the lamp panel.

[0066] Figure 19 It shows Figure 17A second variation of the LED straight tube light is shown in a cross-sectional view along the axial direction, wherein the lamp plate is on the reflective film and the reflective film extends circumferentially along both sides of the lamp plate.

[0067] Figure 20 It shows Figure 17 A cross-sectional view along the axial direction of the third variant of the LED straight tube light, wherein the lamp plate is on the reflective film and the reflective film extends only along the circumference of the lamp tube on one side of the lamp plate.

[0068] Figure 21 It shows Figure 17 A cross-sectional view along the axial direction of the fourth modified example of the LED straight tube light, wherein the lamp plate has reflective films on both sides;

[0069] Figure 22 The present invention illustrates the structure of an LED straight tube lamp in various embodiments of the present invention, in which the lamp board is a flexible circuit board and is welded to the power output terminal at the reinforced part;

[0070] Figure 23 The present invention illustrates that in various embodiments of the LED straight tube lamp, the lamp board has a double-layer flexible circuit board structure.

[0071] Figure 24 The present invention illustrates a three-dimensional structure in an LED straight tube lamp, wherein the lamp board is a flexible circuit board and is soldered to the printed circuit board of the power supply.

[0072] Figure 25 The invention illustrates an embodiment of an LED straight tube lamp with a pad structure of a flexible circuit board.

[0073] Figure 26 An embodiment of the present invention is shown where the LED straight tube lamp board is a flexible circuit board and has a pad structure with three pads arranged in a row.

[0074] Figure 27 An embodiment of the present invention is shown where the LED straight tube lamp board is a flexible circuit board and has a structure of three pads arranged in two rows side by side.

[0075] Figure 28 The present invention illustrates that the LED straight tube lamp has a flexible circuit board with four pads arranged in a row.

[0076] Figure 29 The present invention illustrates that the LED straight tube lamp has a flexible circuit board with four pads arranged in two rows.

[0077] Figure 30 The present invention illustrates an LED straight tube lamp with a flexible circuit board lamp board and a pad structure with holes in the solder pads.

[0078] Figure 31 yes Figure 30 A partial enlarged side cross-sectional view of the flexible circuit board soldered to the power supply's printed circuit board.

[0079] Figure 32 yes Figure 30 A partial enlarged cross-sectional view of the flexible circuit board when the solder pad holes are located near the edge, and it is soldered to the power supply printed circuit board.

[0080] Figure 33 The present invention illustrates an LED straight tube lamp whose lamp board is a flexible circuit board with a pad structure having notched pads.

[0081] Figure 34 It is along Figure 33 Enlarged partial sectional view of the middle AA line;

[0082] Figure 35 This invention illustrates a three-dimensional structure in an LED straight tube lamp, wherein the lamp board is a flexible circuit board and is combined with the printed circuit board of the power supply.

[0083] Figure 36 yes Figure 35 A structural diagram of a variation example;

[0084] Figure 37 The three-dimensional structure of the support in the light source of an LED straight tube lamp according to an embodiment of the present invention is shown. Detailed Implementation

[0085] Based on glass lamp tubes, the inventors of this invention have proposed a new LED straight tube lamp to solve the problems mentioned in the background art and the aforementioned problems.

[0086] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0087] Please refer to Figure 1 and Figure 2 In various embodiments of the present invention, an LED straight tube light is provided, comprising: a tube 1, a lamp plate 2 disposed within the tube 1, and two lamp holders 3 respectively disposed at both ends of the tube 1. The tube 1 can be a plastic tube or a glass tube. In one embodiment, the lamp holders are of the same size, and the LED straight tube light uses a glass tube with a reinforced section to avoid the problems of easy breakage of traditional glass tubes and electric shock accidents caused by leakage due to breakage, as well as the problem of easy aging of plastic tubes. Please refer to... Figure 1A In other embodiments, the size of the lamp head can be different. Preferably, the size of the smaller lamp head is 30% to 80% of the size of the larger lamp head.

[0088] Please refer to Figure 2 With Figure 15 , in one embodiment, the glass tube of the LED straight tube lamp proposed by the present invention has a structurally strengthened end, which is described as follows. The lamp tube 1 includes a main body portion 102 and end portions 101 located at both ends of the main body portion 102 respectively, and the lamp head 3 is sleeved outside the end portion 101. Among them, the outer diameter of at least one end portion 101 is smaller than the outer diameter of the main body portion 102. In this embodiment, it is set that the outer diameters of both end portions 101 are smaller than the outer diameter of the main body portion 102, and the cross-section of the end portion 101 is a plane and parallel to the main body portion 102. Specifically, both ends of the lamp tube 1 are treated through a strengthening portion, and the end portion 101 forms a strengthened portion structure, and the lamp head 3 is sleeved on the strengthened end portion 101, so that the difference between the outer diameter of the lamp head 3 and the outer diameter of the main body portion 102 of the lamp tube becomes smaller, or even completely flush, that is, the outer diameter of the lamp head 3 is equal to the outer diameter of the main body portion 102 and there is no gap between the lamp head 3 and the main body portion 102. The advantage of this setting is that during transportation, the packaging support will not only contact the lamp head 3, but it can also contact the lamp head 3 and the lamp tube 1 simultaneously, making the entire LED straight tube lamp受力均匀 (the force is evenly distributed), rather than making the lamp head 3 the only force-bearing point, avoiding the connection part between the lamp head 3 and the end portion 101 of the lamp tube from cracking due to concentrated force, improving the quality of the product, and having an aesthetic function at the same time.

[0089] The length of the transition portion 103 is 1 mm to 4 mm. If it is less than 1 mm, the strength of the transition portion is insufficient; if it is greater than 4 mm, the length of the main body portion 102 will be reduced, the light-emitting surface will be reduced, and at the same time, the length of the lamp head 3 needs to be increased correspondingly to cooperate with the main body portion 102, resulting in an increase in the material of the lamp head 3. In other embodiments, the transition portion 103 may not be arc-shaped either. Please refer to Figure 5 With Figure 16 , Figure 5 shows a schematic structural diagram when the lamp head 3 and the lamp tube 1 of the embodiment of the present invention are connected, Figure 16 shows Figure 5 the structural schematic diagram of the transition portion 103 of the lamp tube 1 in [[ID=1X]] Figure 5 With Figure 16 shown, in this embodiment, the lamp tube 1 is made of a glass tube. The transition portion 103 between the main body portion 102 and the end portion 101 will slightly呈由连续二个具有曲率半径R1、R2的弧面所构成的倒S形曲面 (be an inverted S-shaped curved surface formed by two consecutive arc surfaces with curvature radii R1 and R2). Generally speaking, the relationship between the curvature radii R1 and R2 of the two arc surfaces is R1 < R2, and the ratio range of R1 to R2, R1:R2, is 1:1.5 to 1:10, the preferred range is 1:2.5 to 1:5, and the best range is 1:3 to 1:4. In this embodiment, R1:R2 is about 1:3. In this way, the transition portion 103 close to the end portion 101 (that is, Figure 16The concave transition portion 103 shown is reinforced so that the glass is in a state of tension on the inner layer and compression on the outer layer, thereby increasing the strength of the transition portion 103 of the glass lamp tube 1. The transition portion 103 near the main body 102 (i.e....) Figure 16 The concave transition portion 103 shown in the figure is strengthened so that the glass is in a state of inner compression and outer tension, thereby increasing the strength of the transition portion 103 of the glass lamp tube 1.

[0090] Please refer to Figure 3 and Figure 4 In one embodiment of the present invention, the lamp head 3 of the LED straight tube lamp includes an insulating tube 302, a heat-conducting part 303 fixed on the outer peripheral surface of the insulating tube 302, and two hollow conductive needles 301 disposed on the insulating tube 302.

[0091] Please refer to Figure 5 In this embodiment, one end of the heat-conducting part 303 extends out of the insulating tube 302 towards the lamp tube. The extended portion of the heat-conducting part 303 (the portion extending out of the insulating tube) is bonded to the lamp tube 1 with a hot melt adhesive 6. Furthermore, the lamp holder 3 extends to the transition portion 103 through the heat-conducting part 303. The close contact between the heat-conducting part 303 and the transition portion 103 ensures that when the heat-conducting part 303 and the lamp tube 1 are bonded with the hot melt adhesive 6, no hot melt adhesive 6 will overflow from the lamp holder 3 and remain on the main body 102 of the lamp tube 1. In addition, the end of the insulating tube 302 facing the lamp tube 1 does not extend to the transition portion 103; that is, a certain distance is maintained between the end of the insulating tube 302 facing the lamp tube and the transition portion 103. In this embodiment, the material of the insulating tube 302 is not limited to plastic, ceramic, or other materials; it is mainly suitable as long as it is not a good conductor of electricity under normal conditions. Furthermore, the hot melt adhesive 6 is a composition containing a welding paste powder, preferably composed of: phenolic resin 2127#, shellac, rosin, calcite powder, zinc oxide, ethanol, etc. In this embodiment, rosin is a tackifier, soluble in ethanol but insoluble in water. This hot melt adhesive 6 can change its physical state and expand significantly under high-temperature heating conditions to achieve a curing effect. Combined with the adhesiveness of the material itself, it can ensure close contact between the lamp holder 3 and the lamp tube 1, facilitating the automated production of LED straight tube lights. In this embodiment, the hot melt adhesive 6 expands and flows after high-temperature heating, and then cures upon cooling. When the hot melt adhesive 6 is heated from room temperature to a temperature of 200 to 250 degrees Celsius, the volume of the hot melt adhesive will expand to 1 to 1.3 times its original size. Of course, the selection of hot melt adhesive components in this invention is not limited to this; components that cure after being heated to a predetermined temperature can also be selected. Since the hot melt adhesive 6 of this invention will not cause a decrease in reliability due to the high temperature environment formed by heat-generating components such as power supply components, it can prevent the adhesion performance between the lamp tube 1 and the lamp holder 3 from decreasing during the use of LED straight tube lamps, thereby improving long-term reliability.

[0092] Specifically, an accommodating space is formed between the inner peripheral surface of the protruding portion of the heat-conducting part 303 and the outer peripheral surface of the lamp tube 1, and hot melt adhesive 6 is filled in the accommodating space. Figure 5 (The position indicated by the dashed line B). In other words, the position filled by the hot melt adhesive 6 is determined by a first virtual plane perpendicular to the axis of the lamp tube 1 (as shown by the dashed line B). Figure 5 The plane (drawn by the dashed line B) passes through the first virtual plane in a radially inward direction, where the heat-conducting part 303, hot melt adhesive 6, and the outer peripheral surface of the lamp tube 1 are arranged sequentially. The hot melt adhesive 6 can be coated with a thickness of 0.2mm to 0.5mm. The hot melt adhesive 6 will expand and solidify, thereby contacting the lamp tube 1 and fixing the lamp head 3 to the lamp tube 1. Because there is a height difference between the outer peripheral surfaces of the end 101 and the main body 102, the hot melt adhesive can be prevented from overflowing onto the main body 102 of the lamp tube, eliminating the need for subsequent manual wiping and increasing the production yield of LED straight tube lights.

[0093] During processing, heat is conducted to the heat-conducting part 303 through an external heating device, and then to the hot melt adhesive 6, which expands and cools and solidifies, thereby fixing the lamp holder 3 to the lamp tube 1.

[0094] In this embodiment, as Figure 5 As shown, the insulating tube 302 includes a first tube 302a and a second tube 302b connected axially. The outer diameter of the second tube 302b is smaller than that of the first tube 302a, and the difference in outer diameter between the two tubes ranges from 0.15mm to 0.3mm. A heat-conducting part 303 is disposed on the outer circumferential surface of the second tube 302b. The outer surface of the heat-conducting part 303 is flush with the outer circumferential surface of the first tube 302a, making the outer surface of the lamp holder 3 smooth and flat, ensuring uniform stress distribution during packaging and transportation of the entire LED straight tube lamp. The ratio of the length of the heat-conducting part 303 along the axial direction of the lamp holder to the axial length of the insulating tube 302 is 1:2.5 to 1:5, i.e., the ratio of the length of the heat-conducting part to the length of the insulating tube is 1:2.5 to 1:5.

[0095] In this embodiment, to ensure a strong bond, the second tube 302b is at least partially fitted over the lamp tube 1, and the accommodating space also includes the space between the inner surface of the second tube 302b and the outer surface of the end 101 of the lamp tube. Hot melt adhesive 6 partially fills the overlapping areas. Figure 5 The location indicated by the dashed line A is between the second tube 302b and the lamp tube 1, meaning that part of the hot melt adhesive 6 is located between the inner surface of the second tube 302b and the outer surface of the end 101. In other words, the location where the hot melt adhesive 6 fills the accommodating space is achieved by a second virtual plane perpendicular to the lamp tube axis (as shown by the dashed line A). Figure 5The plane (drawn by the dashed line A) passes through the second virtual plane in a radially inward direction, and is sequentially arranged as follows: heat-conducting part 303, second tube 302b, hot melt adhesive 6, and end piece 101. It should be noted that in this embodiment, the hot melt adhesive 6 does not need to completely fill the aforementioned accommodating space (as shown, the accommodating space may also include the space between the heat-conducting part 303 and the second tube 302b). During manufacturing, when applying the hot melt adhesive 6 between the heat-conducting part 303 and the end piece 101, the amount of hot melt adhesive can be appropriately increased, so that during subsequent heating, the hot melt adhesive can flow between the second tube 302b and the end piece 101 due to expansion, and after cooling and solidification, it can bond the two together.

[0096] In this design, the end 101 of the lamp tube 1 is inserted into the lamp holder 3. The axial length of the part of the end 101 of the lamp tube 1 inserted into the lamp holder 3 is between one-third and two-thirds of the axial length of the heat-conducting part 303. This has the following advantages: First, it ensures that the hollow conductive needle 301 and the heat-conducting part 303 have sufficient creepage distance, so that they are not likely to short-circuit when energized, causing electric shock and danger. Second, due to the insulation effect of the insulating tube 302, the creepage distance between the hollow conductive needle 301 and the heat-conducting part 303 is increased, making it easier to pass the test that could cause electric shock and danger when energized.

[0097] Furthermore, regarding the hot melt adhesive 6 on the inner surface of the second tube 302b, since the second tube 302b is positioned between the hot melt adhesive 6 and the heat-conducting part 303, the effectiveness of heat transfer from the heat-conducting part 303 to the hot melt adhesive 6 is reduced. Therefore, referring to... Figure 4 In this embodiment, multiple circumferentially arranged notches 302c are provided at the end of the second tube 302b facing the lamp tube 1 (i.e., the end away from the first tube 302a). This increases the contact area between the heat-conducting part 303 and the hot melt adhesive 6, facilitating rapid heat conduction from the heat-conducting part 303 to the hot melt adhesive 6 and accelerating the curing process of the hot melt adhesive 6. Simultaneously, when a user touches the heat-conducting part 303, the insulation effect of the hot melt adhesive 6 between the heat-conducting part 303 and the lamp tube 1 prevents electric shock due to damage to the lamp tube 1.

[0098] The heat-conducting part 303 can be made of various materials that easily conduct heat; in this embodiment, it is a metal sheet, and for aesthetic reasons, it can also be made of aluminum alloy. The heat-conducting part 303 is tubular (or annular) and is fitted over the second tube 302b. The insulating tube 302 can be made of various insulating materials, but it is best if it does not conduct heat easily to prevent heat from being conducted to the power supply components inside the lamp holder 3 and affecting the performance of the power supply components. In this embodiment, the insulating tube 302 is a plastic tube.

[0099] In other embodiments, the heat-conducting part 303 may also consist of a plurality of metal sheets arranged circumferentially or non-interval along the second tube 302b.

[0100] In other embodiments, the lamp holder of the LED straight tube lamp of the present invention may be configured in other forms or include other components, as described below.

[0101] Please refer to Figure 6 In another embodiment of the present invention, the lamp holder 3 includes an insulating tube 302 and a magnetically conductive metal part 9, but does not include the aforementioned heat-conducting part. The magnetically conductive metal part 9 is fixed on the inner circumferential surface of the insulating tube 302, and is at least partially located between the inner circumferential surface of the insulating tube 302 and the end of the lamp tube, and has a radially overlapping portion with the lamp tube 1.

[0102] In this embodiment, the entire magnetically conductive metal component 9 is located inside the insulating tube 302. Hot melt adhesive 6 is applied to the inner surface of the magnetically conductive metal component 9 (the surface of the magnetically conductive metal component 9 facing the lamp tube 1) and bonded to the outer peripheral surface of the lamp tube 1. In order to increase the bonding area and improve the bonding stability, the hot melt adhesive 6 preferably covers the entire inner surface of the magnetically conductive metal component 9.

[0103] Please refer to Figure 7 In this embodiment, during the manufacturing of the LED straight tube lamp, the insulating tube 302 of the lamp holder 3 is inserted into an external heating device, preferably an induction coil 11, such that the induction coil 11 is located above the magnetic metal part 9 and is radially opposite to the magnetic metal part 9 along the insulating tube 302. During processing, the induction coil 11 is energized, and an electromagnetic field is formed after the induction coil 11 is energized. The electromagnetic field is converted into current after passing through the magnetic metal part 9, causing the magnetic metal part 9 to heat up. That is, the magnetic metal part 9 is heated by electromagnetic induction technology, and the heat is conducted to the hot melt adhesive 6. The hot melt adhesive 6 absorbs heat, expands and flows, and after cooling, the hot melt adhesive 6 solidifies, thereby achieving the purpose of fixing the lamp holder 3 to the lamp tube 1. In this embodiment, the induction coil 11 is a ring coil made of metal wire with a width of 5mm to 6mm, mainly made of copper. The diameter of the ring coil is about 30mm to 35mm, and the lower limit of the diameter of the ring coil is slightly larger than the outer diameter of the lamp holder 3. Assuming the outer diameter of the lamp holder 3 is the same as that of the lamp tube 1, the outer diameter of the lamp holder 3 will vary depending on the type of lamp tube 1. Therefore, different types of lamp tubes can use induction coils 11 with different diameters. For example, the diameter of the T12 lamp tube is 38.1 mm, the diameter of the T10 lamp tube is 31.8 mm, the diameter of the T8 lamp tube is 25.4 mm, the diameter of the T5 lamp tube is 16 mm, the diameter of the T4 lamp tube is 12.7 mm, and the diameter of the T2 lamp tube is 6.4 mm.

[0104] Furthermore, the induction coil 11 is supplied with alternating current, with a power of 15kW to 25kW and a frequency of 25kHz to 35kHz. Preferably, the power is 20kW and the frequency is 30kHz. Further, the induction coil 11 can be used in conjunction with a power amplification unit to amplify the power of the alternating current by 1 to 2 times. The current received by the induction coil 11 is 25A to 35A, preferably 32.5A, and the continuous energizing time of the induction coil 11 is 2 seconds to 10 seconds, preferably 5 seconds. The induction coil 11 is coaxial with the insulating tube 302 as much as possible to ensure more uniform energy transfer. In this embodiment, the deviation between the induction coil 11 and the central axis of the insulating tube 302 does not exceed 0.05mm. After bonding, the lamp tube 1 along with the lamp holder 3 is removed from the induction coil 11. In this embodiment, the hot melt adhesive 6 expands and flows after absorbing heat, and then solidifies upon cooling. In this embodiment, the heating temperature of the magnetically conductive metal part 9 can reach 250 to 300 degrees Celsius, while the heating temperature of the hot melt adhesive 6 can reach 200 to 250 degrees Celsius. Of course, the selection of hot melt adhesive components in this invention is not limited to this; components that solidify immediately after absorbing heat can also be selected.

[0105] In this embodiment, after the manufacturing process of the lamp tube 1 is completed, the induction coil 11 is kept stationary while the lamp tube 1 and lamp holder 3 are removed from the induction coil 11. However, in other embodiments, the lamp tube 1 can also be kept stationary while the induction coil 11 is removed from the lamp tube. In this embodiment, the heating device for the magnetic metal component 9 can be a device with a plurality of induction coils 11. That is, when it is desired to heat the lamp holders 3 of a plurality of lamp tubes 1, it is only necessary to place the plurality of lamp tubes 1 in the default position. Then, the heating device will move the corresponding induction coil 11 to the lamp holder position of the lamp tube 1 to be heated. After heating is completed, the plurality of induction coils 11 will be removed from the corresponding lamp tube 1 to complete the heating of the magnetic metal component 9. However, in these embodiments, the relative movement between the induction coil 11 and the lamp holder 3, whether the induction coil 11 is placed in a fixed position and the lamp holder 3 is moved and inserted into the induction coil 11, or the lamp holder 3 is placed in a fixed position and the induction coil 11 is moved to insert the lamp holder 3 into the induction coil 11, is a relative movement in the front-back direction. Since the length of the lamp tube 1 is much greater than the length of the lamp holder 3, and in some special applications the length of the lamp tube 1 can even reach more than 240cm, when the lamp tube 1 and the lamp holder 3 move together, the connection and fixation between the lamp holder 3 and the lamp tube 1 may be damaged due to positional errors when the induction coil 11 and the lamp holder 3 are pulled in or out relative to each other.

[0106] Please refer to Figure 6To better support the magnetically conductive metal component 9, the inner diameter of the portion 302d on the inner circumferential surface of the insulating tube 302 used to support the magnetically conductive metal component 9 is larger than the inner diameter of the remaining portion 302e. A step is formed at the junction of 302d and 302e. One axial end of the magnetically conductive metal component 9 rests against the step, ensuring that the entire inner surface of the lamp holder is flush after the magnetically conductive metal component 9 is installed. Furthermore, the magnetically conductive metal component 9 can be of various shapes, such as circumferentially arranged sheets or tubes. Here, the magnetically conductive metal component 9 is arranged in a tube shape coaxial with the insulating tube 302.

[0107] Please refer to Figure 8 , Figure 9 In other embodiments, the portion of the inner circumferential surface of the insulating tube 302 used to support the magnetically conductive metal part 9 can also be in the following form: the inner circumferential surface of the insulating tube 302 has a support portion 313 protruding toward the interior of the insulating tube 302, and a protrusion 310 is also provided on the inner circumferential surface of the insulating tube 302 on the side of the support portion 313 facing the lamp tube body portion, the radial thickness of the protrusion 310 being less than the radial thickness of the support portion 313. Figure 9 As shown, the protrusion 310 is axially connected to the support 313. The magnetic metal part 9 abuts against the upper edge of the support 313 (i.e., the end face of the support facing the protrusion) in the axial direction and against the radially inner side of the protrusion 310 in the circumferential direction. That is, at least a portion of the protrusion 310 is located between the magnetic metal part 9 and the inner circumferential surface of the insulating tube 302. The protrusion 310 can be an annular shape extending circumferentially along the insulating tube 302, or a plurality of protrusions arranged circumferentially at intervals around the inner circumferential surface of the insulating tube 302. Furthermore, the protrusions can be arranged at equal or unequal intervals in the circumferential direction, as long as the contact area between the outer surface of the magnetic metal part 9 and the inner circumferential surface of the insulating tube 302 is reduced, while still having the function of retaining the hot melt adhesive 6.

[0108] Preferably, the thickness of the support portion 313 protruding inward from the inner circumference of the insulating tube 302 is 1 mm to 2 mm, and the thickness of the protrusion 310 is less than the thickness of the support portion 313, with the thickness of the protrusion 310 being 0.2 mm to 1 mm.

[0109] In other embodiments, the lamp holder 3 can also be made entirely of metal. In this case, an insulator needs to be added to the lower part of the hollow conductive needle to withstand high voltage.

[0110] Please refer to Figure 10In other embodiments, the surface of the magnetically conductive metal part 9 facing the insulating tube 302 has at least one hollow structure 91. The shape of the hollow structure 91 is circular, but not limited to circular; it can be, for example, elliptical, square, star-shaped, etc., as long as it can reduce the contact area between the magnetically conductive metal part 9 and the inner circumferential surface of the insulating tube 302, while still having the function of thermosetting, i.e., heating the hot melt adhesive 6. Preferably, the area of ​​the hollow structure 91 accounts for 10% to 50% of the area of ​​the magnetically conductive metal part 9. The hollow structures 91 can be arranged at equal intervals around the circumference or at unequal intervals, etc.

[0111] Please refer to Figure 11 In other embodiments, the surface of the magnetically conductive metal part 9 facing the insulating tube 302 has an indentation structure 93. The indentation structure 93 can be a structure that protrudes from the inner surface of the magnetically conductive metal part 9 to the outer surface, or it can be a structure that protrudes from the outer surface of the magnetically conductive metal part 9 to the inner surface. The purpose is to form a protrusion or depression on the outer surface of the magnetically conductive metal part 9 to reduce the contact area between the outer surface of the magnetically conductive metal part 9 and the inner circumferential surface of the insulating tube 302. That is, the surface shape of the magnetically conductive metal part 9 can be selected from one of the group consisting of a hollow structure, a raised structure, and a recessed structure to reduce the contact area between the outer surface of the magnetically conductive metal part 9 and the inner circumferential surface of the insulating tube 302. However, it should be noted that the magnetically conductive metal part 9 should be stably bonded to the lamp tube to achieve the function of the thermosetting hot melt adhesive 6.

[0112] Please refer to Figure 12 In this embodiment, the magnetically conductive metal component 9 is a circular ring. Please refer to... Figure 13 In other embodiments, the magnetically conductive metal part 9 is a non-circular ring, such as, but not limited to, an elliptical ring. When the lamp tube 1 and the lamp holder 3 are elliptical, the minor axis of the elliptical ring is slightly larger than the outer diameter of the lamp tube end, thereby reducing the contact area between the outer surface of the magnetically conductive metal part 9 and the inner circumferential surface of the insulating tube 302, while still achieving the function of thermosetting the hot melt adhesive 6. In other words, the inner circumferential surface of the insulating tube 302 has a support portion 313, and the non-circular magnetically conductive metal part 9 is disposed on the support portion 313. Therefore, the contact area between the magnetically conductive metal part 9 and the inner circumferential surface of the insulating tube 302 can be reduced, while still achieving the function of curing the hot melt adhesive 6. It should be noted that in other embodiments, the magnetically conductive metal part 9 can also be disposed outside the lamp holder 3, instead of, for example, Figure 5 The heat-conducting part 303 shown can also achieve the function of curing hot melt adhesive 6 through the principle of electromagnetic induction.

[0113] In other embodiments, the lamp holder includes a power slot (not shown) for mounting a power supply assembly.

[0114] To facilitate the connection and fixation of the lamp holder 3 and the lamp tube 1, this embodiment has made improvements to the lamp holder 3.

[0115] Please refer to Figure 3-5 and combined Figure 6-9 When the lamp holder 3 is fitted outside the lamp tube 1, the lamp holder 3 is fitted outside the end 101 of the lamp tube 1 and extends to the transition portion 103, partially overlapping with the transition portion 103. In this embodiment, the lamp holder 3 includes two hollow conductive needles 301.

[0116] Please refer to Figure 14 In another embodiment, the end of the lamp holder 3' is provided with a protrusion 312, the top of which has a hole, and the outer edge of which has a groove 313 with a depth of 0.1 mm for positioning the conductive pin 53. After the conductive pin 53 passes through the hole of the protrusion 312 at the end of the lamp holder 3', it can be bent and placed on the groove 313, and then a conductive metal cap 311 is used to cover the protrusion 312. In this way, the conductive pin 53 can be fixed between the protrusion 312 and the conductive metal cap 311. In this embodiment, the inner diameter of the conductive metal cap 311 is, for example, 7.56 mm, the outer diameter of the protrusion 312 is, for example, 7.23 mm, and the outer diameter of the conductive pin 53 is, for example, 0.5 mm. Therefore, the conductive metal cap 311 can directly and tightly cover the protrusion 312 without the need for additional adhesive, thus completing the electrical connection between the power supply 5 and the conductive metal cap 311.

[0117] Please refer to Figure 2 , 3 In other embodiments, such as 12 and 13, the lamp holder provided by the present invention is provided with holes 304 for heat dissipation. This allows the heat generated by the power supply components inside the lamp holder to dissipate without causing the inside of the lamp holder to be at a high temperature, thereby preventing a decrease in the reliability of the internal components.

[0118] Reference Figure 17 In this embodiment, in addition to the lamp board 2 (or flexible circuit board) that is closely attached to the lamp tube 1, the lamp tube 1 also includes a diffusion layer 13. The light generated by the light source 202 passes through the diffusion layer 13 and then exits the lamp tube 1.

[0119] The diffusion layer 13 diffuses the light emitted by the light source 202. Therefore, as long as the light can pass through the diffusion layer 13 and then exit the lamp tube 1, the arrangement of the diffusion layer 13 can take many forms. For example, the diffusion layer 13 can be coated or covered on the inner circumferential surface of the lamp tube 1, or coated or covered on the surface of the light source 202 with a diffusion coating (not shown in the figure), or used as an outer cover to cover (or shield) the light source 202 with a diffusion film.

[0120] Please refer to this again. Figure 17When the diffusion layer 13 is a diffusion film, it can cover the light source 202 without contacting it. The common term for diffusion film is optical diffusion sheet or optical diffusion plate. It is usually a composite material formed by combining one or more of PS polystyrene, PMMA polymethyl methacrylate, PET (polyethylene terephthalate), and PC (polycarbonate) with diffusion particles. When light passes through the composite material, it can cause a diffusion phenomenon, which can correct the light into a uniform surface light source to achieve the effect of optical diffusion and ultimately make the brightness of the lamp tube uniformly distributed.

[0121] When the diffusion layer 13 is a diffusion coating, its main components can be any one of calcium carbonate, calcium halophosphate, and alumina, or a combination of any two or three of them. A diffusion coating formed using calcium carbonate as the main material and a suitable solution will have excellent diffusion and light transmission (potentially reaching over 90%). Furthermore, it has been found that lamp holders bonded to the tempered glass sometimes have quality issues, with a small percentage prone to detachment. However, by applying this diffusion coating to the outer surface of the lamp tube end 101, the friction between the diffusion coating and the hot melt adhesive 6 increases, making the friction between the diffusion coating and the hot melt adhesive 6 greater than the friction between the end face of the lamp tube end 101 and the hot melt adhesive when the diffusion coating is not applied. Therefore, the problem of the lamp holder 3 detaching is significantly solved by the friction between the diffusion coating and the hot melt adhesive 6.

[0122] In this embodiment, the components of the diffusion coating during preparation include calcium carbonate, strontium phosphate (e.g., CMS-5000, white powder), thickener, and ceramic activated carbon (e.g., ceramic activated carbon SW-C, colorless liquid).

[0123] Specifically, the diffusion coating, primarily composed of calcium carbonate, is mixed with a thickener, ceramic activated carbon, and deionized water and applied to the inner circumferential surface of the glass lamp tube. The average coating thickness is between 20 and 30 μm. The deionized water evaporates, leaving only calcium carbonate, the thickener, and the ceramic activated carbon. The diffusion layer 13 formed using this material can have approximately 90% light transmittance, typically ranging from 85% to 96%. In addition to its light-diffusing effect, the diffusion layer 13 also provides electrical isolation, reducing the risk of electric shock to users should the glass lamp tube break. Furthermore, the diffusion layer 13 allows the light from the light source 202 to diffuse in all directions, illuminating the area behind the light source 202, near the flexible circuit board, thus preventing dark areas within the lamp tube 1 and improving the lighting comfort of the space. In addition, when choosing diffusion coatings with different material compositions, there is another possible implementation method: the diffusion layer thickness can be in the range of 200μm to 300μm, and the light transmittance can be controlled between 92% and 94%, which will also have a different effect.

[0124] In other embodiments, the diffusion coating can also be based on calcium carbonate, combined with a small amount of reflective material (such as strontium phosphate or barium sulfate), thickener, ceramic activated carbon, and deionized water. This mixture is then applied to the inner circumferential surface of the glass tube, with an average thickness between 20 and 30 μm. Finally, the deionized water evaporates, leaving only calcium carbonate, reflective material, thickener, and ceramic activated carbon. Since the purpose of the diffusion layer is to diffuse light, and diffusion, at a microscopic level, is the reflection of light by particles, the particle size of reflective materials such as strontium phosphate or barium sulfate is much larger than that of calcium carbonate. Therefore, adding a small amount of reflective material to the diffusion coating can effectively increase the light diffusion effect. Of course, in other embodiments, calcium halophosphate or alumina can also be selected as the main material of the diffusion coating. The particle size of calcium carbonate is approximately between 2 and 4 μm, while the particle sizes of calcium halophosphate and alumina are approximately between 4 and 6 μm and 1 and 2 μm, respectively. Taking calcium carbonate as an example, when the required light transmittance is between 85% and 92%, the average thickness of the diffusion coating with calcium carbonate as the main material is approximately 20 to 30 μm. Under the same light transmittance requirement range (85% to 92%), the average thickness of the diffusion coating with calcium halophosphate as the main material will be between 25 and 35 μm, and the average thickness of the diffusion coating with alumina as the main material will be between 10 and 15 μm. If the light transmittance requirement is higher, such as above 92%, the thickness of the diffusion coating with calcium carbonate, calcium halophosphate, or alumina as the main material needs to be thinner. Taking the diffusion coating with calcium carbonate as the main material as an example, its average coating thickness is between 10 and 15 μm.

[0125] In other words, depending on the application of lamp tube 1 and the required light transmittance, the main material and thickness of the diffusion coating can be selected. It should be noted that the higher the light transmittance of the diffusion layer, the more noticeable the graininess of the light source will be to the user.

[0126] In other embodiments, the width of the flexible circuit board can be increased. Since the surface of the circuit board includes a circuit protective layer of ink material, and the ink material has the function of reflecting light, the circuit board itself can function as a reflective film 12 in the widened portion. Preferably, the ratio between the length of the flexible circuit board extending circumferentially along the lamp tube 2 and the circumference of the inner circumference of the lamp tube 2 is in the range of 0.3 to 0.5. A circuit protective layer can be covered on the outside of the flexible circuit board. The circuit protective layer can be an ink material that has the function of increasing reflection. The widened flexible circuit board extends circumferentially from the light source, and the light from the light source will be more concentrated through the widened portion.

[0127] In other embodiments, the inner circumferential surface of the glass tube may be entirely coated with a diffusion coating, or only partially coated (excluding the area with the reflective film 12). In either case, the diffusion coating should preferably be applied to the outer surface of the end of the lamp tube 1 to make the adhesion between the lamp holder 3 and the lamp tube 1 stronger.

[0128] It should be added that, in the above embodiments of the present invention, one of the group consisting of a diffusion coating, a diffusion film and an adhesive film can be used for the optical processing of the light emitted by the light source of the present invention.

[0129] Please continue to refer to Figure 2 In one embodiment of the present invention, the LED straight tube lamp further includes an adhesive sheet 4, a lamp board insulating film 7, and a light source film 8. The lamp board 2 is adhered to the inner circumferential surface of the lamp tube 1 by the adhesive sheet 4. As shown in the figure, the adhesive sheet 4 can be silicone, and its form is not limited; it can be several segments as shown in the figure, or a long strip. Various forms of adhesive sheets 4, various forms of lamp board insulating films 7, and various forms of light source films 8 can be combined to constitute different embodiments of the present invention.

[0130] An insulating film 7 is applied to the surface of the lamp panel 2 facing the light source 202, preventing the lamp panel 2 from being exposed and thus providing insulation to isolate the lamp panel 2 from the outside environment. During the application of the film, a through-hole 71 corresponding to the light source 202 is pre-drilled, and the light source 202 is positioned within the through-hole 71. The insulating film 7 is composed of vinyl polysiloxane, hydrogen-based polysiloxane, and aluminum oxide. The thickness of the insulating film 7 ranges from 100 μm to 140 μm (micrometers). If it is less than 100 μm, it will not provide sufficient insulation; if it is greater than 140 μm, it will result in material waste.

[0131] A light source film 8 is coated onto the surface of the light source 202. The light source film 8 is transparent to ensure high light transmittance. After being coated onto the surface of the light source 202, the shape of the light source film 8 can be granular, strip-shaped, or sheet-like. The parameters of the light source film 8 include refractive index and thickness. The allowable range of the refractive index of the light source film 8 is 1.22 to 1.6. If the refractive index of the light source film 8 is the square root of the refractive index of the light source 202 housing, or if the refractive index of the light source film 8 is ±15% of the square root of the refractive index of the light source 202 housing, then the light transmittance is better. Here, the light source housing refers to the housing that houses the LED chip (or dies). In this embodiment, the refractive index range of the light source film 8 is 1.225 to 1.253. The allowable thickness range of the light source film 8 is 1.1 mm to 1.3 mm. If it is less than 1.1 mm, it will not cover the light source 202, resulting in poor performance; if it is greater than 1.3 mm, it will reduce light transmittance and increase material costs.

[0132] During assembly, first apply the light source film 8 to the surface of the light source 202; then apply the lamp board insulating film 7 to one side surface of the lamp board 2; then fix the light source 202 to the lamp board 2; next, use adhesive sheet 4 to adhere and fix the side surface of the lamp board 2 opposite to the light source 202 to the inner circumference of the lamp tube 1; finally, fix the lamp holder 3 to the end of the lamp tube 1, and simultaneously connect the light source 202 to the power supply 5. Alternatively, as follows... Figure 22 As shown, the flexible circuit board 2 is soldered to the power supply 5 by passing through the transition section 103 (i.e., soldering to the power supply 5 through the transition section 103), or the lamp board 2 is electrically connected to the power supply 5 by a traditional wire bonding method. Finally, the lamp holder 3 is connected via... Figure 5 (use Figures 3-4 (structure) or Figure 7 (use Figure 6 The structure is connected to the reinforced transition section 103 in a manner that forms a complete LED straight tube light.

[0133] In this embodiment, the lamp board 2 is fixed to the inner circumferential surface of the lamp tube 1 by an adhesive sheet 4, so that the lamp board 2 is attached to the inner circumferential surface of the lamp tube 1. This increases the beam angle of the entire LED tube lamp and expands the viewing angle. This arrangement can generally make the viewing angle exceed 330 degrees. By applying lamp board insulating film 7 to the lamp board 2 and applying insulating light source film 8 to the light source 202, the entire lamp board 2 is insulated. In this way, even if the lamp tube 1 breaks, there will be no electric shock accident, thus improving safety.

[0134] Furthermore, in other embodiments, an adhesive film (not shown) may be applied to the inner or outer circumferential surface of the lamp tube 1 to isolate the exterior and interior of the lamp tube 1 after it breaks. In this embodiment, the adhesive film is applied to the inner circumferential surface of the lamp tube 1.

[0135] In this embodiment, the thickness of the adhesive film ranges from 100 μm to 140 μm. If the adhesive film thickness is less than 100 μm, the explosion-proof performance is insufficient; when the glass breaks, the entire lamp tube will crack. If the thickness is greater than 140 μm, it will reduce the light transmittance and increase material costs. If the requirements for explosion-proof performance and light transmittance are less stringent, the thickness range of the adhesive film can be increased to 10 μm to 800 μm.

[0136] In this embodiment, because the inside of the lamp tube is coated with an adhesive film, after the glass lamp tube breaks, the adhesive film will bind the fragments together and will not form a through hole between the inside and outside of the lamp tube. This prevents the user from contacting the live parts inside the lamp tube 1, thus avoiding electric shock accidents. At the same time, the adhesive film with the above-mentioned ratio also has the function of diffusing light and transmitting light, improving the light emission uniformity and light transmittance of the entire LED straight tube lamp. The adhesive film of this embodiment can be used in conjunction with the aforementioned adhesive sheet 4, lamp board insulating film 7, and light source film 8 to constitute various different embodiments of the present invention.

[0137] It should be noted that since the lamp board 2 in this embodiment is a flexible circuit board, the adhesive film may not be required.

[0138] Furthermore, the lamp board 2 can be any one of a strip aluminum substrate, an FR4 board, or a flexible circuit board. Since the lamp tube 1 in this embodiment is a glass tube, if the lamp board 2 uses a rigid strip aluminum substrate or an FR4 board, when the lamp tube breaks, for example, into two pieces, the entire tube will still remain straight. Users might then believe the LED straight tube light is still usable and attempt to install it themselves, potentially leading to electric shock. Because flexible circuit boards have strong flexibility and bendability, they address the insufficient flexibility and bendability of rigid strip aluminum substrates and FR4 boards. Therefore, the lamp board 2 in this embodiment uses a flexible circuit board. This way, when the lamp tube 1 breaks, it cannot support the broken tube 1 to remain straight, informing the user that the LED straight tube light is no longer usable and preventing electric shock. Therefore, using a flexible circuit board can alleviate the electric shock problem caused by broken glass tubes to a certain extent. The following embodiment uses a flexible circuit board as the lamp board 2 for illustration.

[0139] Please refer to Figure 23 The flexible circuit board 2, serving as the lamp panel 2, includes a conductive circuit layer 2a. The light source 202 is disposed on the circuit layer 2a and is electrically connected to the power supply through the circuit layer 2a. (Refer to...) Figure 23In this embodiment, the flexible circuit board may further include a dielectric layer 2b, stacked on top of the circuit layer 2a. The dielectric layer 2b and the circuit layer 2a have the same area. The surface of the circuit layer 2a opposite to the dielectric layer 2b is used to set the light source 202, and the surface of the dielectric layer 2b opposite to the circuit layer 2a is bonded to the inner circumferential surface of the lamp tube 1 by an adhesive sheet 4. The circuit layer 2a may be a metal layer or a power layer with wires (e.g., copper wires) laid on it.

[0140] In other embodiments, the outer surfaces of the circuit layer 2a and the dielectric layer 2b can be covered with a circuit protection layer, which can be an ink material with solder resist and reflective properties. Alternatively, the flexible circuit board can be a single-layer structure, consisting of only one circuit layer 2a, with the aforementioned ink material covering the surface of the circuit layer 2a as the circuit protection layer. Both single-layer circuit layer 2a and two-layer structures (one circuit layer 2a and one dielectric layer 2b) can be paired with a circuit protection layer. The circuit protection layer can also be provided on one side of the flexible circuit board, for example, only on the side with the light source 202. It should be noted that a flexible circuit board with a single-layer circuit layer 2a or a two-layer structure (one circuit layer 2a and one dielectric layer 2b) is significantly more flexible and bendable than a typical three-layer flexible substrate (two circuit layers with a dielectric layer sandwiched between them). Therefore, it can be paired with a specially shaped lamp tube 1 (e.g., a non-straight lamp), with the flexible circuit board tightly attached to the wall of the lamp tube 1. In addition, the best configuration is for the flexible circuit board to be closely attached to the wall of the lamp tube. The fewer the layers of the flexible circuit board, the better the heat dissipation effect, the lower the material cost, the more environmentally friendly, and the flexibility may also be improved.

[0141] Of course, the flexible circuit board of the present invention is not limited to a single or double-layer circuit board. In other embodiments, the flexible circuit board includes multiple circuit layers 2a and multiple dielectric layers 2b. The dielectric layers 2b and circuit layers 2a are sequentially staggered and disposed on the side opposite to the light source 202 of the circuit layers 2a. The light source 202 is disposed on the top layer of the multiple circuit layers 2a and is electrically connected to the power supply through the top layer of the circuit layers 2a. In other embodiments, the length of the flexible circuit board 2, which serves as the lamp board 2, is greater than the length of the lamp tube.

[0142] Please continue to refer to Figure 2The lamp panel 2 is provided with several light sources 202, and the lamp holder 3 is provided with a power supply 5. The light sources 202 and the power supply 5 are electrically connected through the lamp panel 2. In various embodiments of the present invention, the power supply 5 can be a single unit (i.e., all power supply components are integrated into one component) and located in the lamp holder 3 at one end of the lamp tube 1; or the power supply 5 can be divided into two parts, referred to as a dual unit (i.e., all power supply components are respectively located in two components), and the two parts are respectively located in the lamp holders 3 at both ends of the lamp tube. If only one end of the lamp tube 1 is treated as a reinforced part, the power supply is preferably selected as a single unit and located in the lamp holder 3 corresponding to the reinforced end 101.

[0143] Whether it's a single unit or two units, there are multiple options for how the power supply is formed. For example, the power supply can be a potted module. Specifically, a high thermal conductivity silicone (thermal conductivity ≥0.7w / m·k) is used to pot the power supply component through a mold to obtain the power supply. This method of obtaining a power supply has the advantages of high insulation, high heat dissipation, and a more regular shape, and it can be easily integrated with other structural components. Alternatively, the power supply can be formed without potting, directly placing the exposed power supply component inside the lamp holder, or wrapping the exposed power supply component with traditional heat shrink tubing before placing it inside the lamp holder 3.

[0144] If the two ends of the lamp board 2 along the axial direction of the lamp tube 1 are not fixed to the inner circumference of the lamp tube 1, and a wire connection is used, the free ends will easily cause shaking during subsequent handling, potentially leading to wire breakage. Therefore, welding is the preferred connection method between the lamp board 2 and the power supply 5. Specifically, refer to... Figure 22 The lamp board 2 can be directly soldered to the output terminal of the power supply 5 after passing through the transition section 103 of the reinforcing structure, eliminating the need for wires and improving product quality stability. In this case, the lamp board 2 does not need a female connector 201, and the output terminal of the power supply 5 does not need a male connector 51. The specific method can be as follows: Figure 24 As shown, a power pad a is provided at the output end of power supply 5, and solder is left on power pad a to increase the thickness of the solder on the pad, facilitating soldering. Correspondingly, a light source pad b is also provided at the end of lamp board 2, and the power pad a at the output end of power supply 5 is soldered together with the light source pad b of lamp board 2. If the plane containing the pads is defined as the front side, then the connection between lamp board 2 and power supply 5 is most stable when the pads on their front sides are joined. However, during soldering, the soldering head must press against the back side of lamp board 2, heating the solder through lamp board 2, which can easily lead to reliability issues. If... Figure 25 As shown, a hole is made in the middle of the light source pad b on the front of the lamp board 2, and then it is stacked on the power pad a on the front of the power supply 5 with its front side facing up for soldering. The soldering head can directly heat and melt the solder, which is relatively easy to implement in practice.

[0145] If both ends of the flexible circuit board are fixed to the inner circumference of the lamp tube 1, it is preferable to set the female plug 201 on the flexible circuit board, and then insert the male plug 51 of the power supply 5 into the female plug 201 to achieve electrical connection.

[0146] like Figure 24 As shown in the above embodiment, the flexible circuit board of the lamp board 2 is mostly fixed to the inner circumferential surface of the lamp tube 1, except for both ends which are not fixed to the inner circumferential surface of the lamp tube 1. The lamp board 2 that is not fixed to the inner circumferential surface of the lamp tube 1 forms a free part 21. During assembly, the free part 21 and the end welded to the power supply 5 will cause the free part 21 to shrink into the lamp tube 1. The free part 21 of the lamp board 2 will deform due to shrinkage. Using the above-mentioned lamp board 2 with perforated pads, the side of the lamp board 2 with the light source and the power pad a welded to the power supply 5 are facing the same side. When the free part 21 of the lamp board 2 deforms due to shrinkage, the end of the lamp board 2 and the power supply 5 welded to the power supply 5 has a lateral pulling force on the power supply 5. Compared with the welding method where the side of the lamp board 2 with the light source 202 and the power pad a welded to the power supply 5 are facing different sides, the end of the lamp board 2 and the power supply 5 welded to the power supply 5 also has a downward pulling force. Using the above-mentioned lamp board 2 with perforated pads, the structural electrical connection fixing and reinforcement has a better effect. In this embodiment, the light source pad b of the lamp board 2 is located on the other side of the lamp board 2 where the light source is located, and the light source pad b of the lamp board 2 and the power supply pad a of the power supply 5 are correspondingly soldered and fixed. During assembly, the free part 21 of the lamp board 2 contracts and deforms towards the inside of the lamp tube 1, and the free part 21 that is deformed by force is located on the same side of the lamp board 2 where the light source is located. It is worth noting that when the aforementioned flexible circuit board as the lamp board 2 has a structure of two circuit layers sandwiching a dielectric layer, the aforementioned lamp board 2 without the light source 202 and protruding from the end area of ​​the lamp tube 1 can serve as the free part 21, allowing the free part 21 to realize the connection of the two circuit layers and the circuit layout of the power supply components.

[0147] like Figure 25 As shown, the light source pad b of the lamp board 2 consists of two unconnected pads, which are electrically connected to the positive and negative terminals of the light source 202, respectively. The size of the pads is approximately 3.5 × 2 mm. 2 The printed circuit board of power supply 5 also has corresponding solder pads. A pre-filled solder layer is provided above the solder pads to facilitate automatic soldering by the soldering machine. The solder thickness can be 0.1 to 0.7 mm, with 0.3 to 0.5 mm being more appropriate, and 0.4 mm being optimal. An insulating hole c can be provided between the two solder pads to prevent electrical short circuits caused by the solder fusing together during soldering. Furthermore, a positioning hole d can be provided behind the insulating hole c to allow the automatic soldering machine to correctly determine the position of the light source pad b.

[0148] The light source pad b of the lamp board has at least one solder pad, which is electrically connected to the positive and negative terminals of the light source 202 respectively. In other embodiments, to achieve compatibility and expandability for future use, the number of light source pads b can be more than one solder pad, such as 1, 2, 3, 4 or more. When there is only one solder pad, both ends of the lamp board are electrically connected to the power supply to form a circuit. In this case, electronic components can be used to replace the capacitor, for example, an inductor can replace the capacitor as a current stabilizing component. Figures 26 to 28 As shown, when there are 3 pads, the third pad can be used for grounding; when there are 4 pads, the fourth pad can be used as a signal input terminal. Correspondingly, the power pad a also has the same number of pads as the light source pad b. When there are more than 3 pads, the pads can be arranged in a single row or two rows, positioned appropriately according to the available space, as long as they do not short-circuit with each other. In other embodiments, if part of the circuitry is fabricated on a flexible circuit board, the light source pad b can have only a single pad. Fewer pads result in fewer manufacturing steps; more pads strengthen the electrical connection between the flexible circuit board and the power output terminal.

[0149] like Figure 30 As shown, in other embodiments, the pad of the light source pad b may have a solder through-hole e structure inside. The diameter of the solder through-hole e can be 1 to 2 mm, preferably 1.2 to 1.8 mm, and most preferably 1.5 mm. If it is too small, the solder will not be able to pass through easily. When the power pad a of the power supply 5 is soldered together with the light source pad b of the lamp board 2, the solder can pass through the solder through-hole e and then accumulate on top of the solder through-hole e to cool and solidify, forming a solder ball structure g with a diameter larger than that of the solder through-hole e. This solder ball structure g will function like a nail, not only fixing through the solder between the power pad a and the light source pad b, but also enhancing the stability of the electrical connection due to the effect of the solder ball structure g.

[0150] like Figures 31 to 32 As shown, in other embodiments, when the soldering through-hole e of the light source pad b is ≤1mm from the edge of the lamp board 2, the solder will pass through the hole e and accumulate at the upper edge of the hole. Excess solder will also flow back down from the edge of the lamp board 2 and then solidify with the solder on the power supply pad a. Its structure is like a rivet firmly fixing the lamp board 2 to the circuit board of the power supply 5, providing a reliable electrical connection. Furthermore, if the diameter of the soldering through-hole e is too small, it will hinder the solder from passing through the hole. Therefore, the soldering through-hole e of the light source pad b can also be directly changed to... Figure 33 and Figure 34The solder notch f is used to electrically connect and fix the power pad a and the light source pad b through the solder notch f. The solder can more easily climb onto the light source pad b and accumulate around the solder notch f. When it cools and solidifies, more solder will form solder balls with a diameter larger than the solder notch f. This solder ball structure will enhance the fixing ability of the electrical connection structure.

[0151] In other embodiments, the solder perforation of the pad is at the edge, that is, the pad has a solder notch. The soldering tin passes through the solder notch to electrically connect and fix the power pad a and the light source pad b. The tin will accumulate around the solder perforation. When cooled, it will form a solder ball with a diameter larger than the solder perforation. This solder ball structure will form a structural electrical connection fixation reinforcement. In this embodiment, due to the design of the solder notch, the soldering tin acts like a C-shaped nail.

[0152] Whether the solder pads are pre-formed or directly punched through by the soldering head during the soldering process, the structure described in this embodiment can be achieved. The surface of the soldering head that contacts the solder can be a flat surface or a surface with recesses and protrusions. The protrusions can be elongated or grid-like. The protrusions do not completely cover the perforation, ensuring that the solder can pass through. When the solder passes through the solder perforation and accumulates around it, the recesses provide a place to accommodate the solder balls. In other embodiments, the flexible circuit board 2 has a positioning hole through which the solder pads of the power pad a and the light source pad b can be precisely positioned during soldering.

[0153] Please refer to Figure 35 and Figure 36 In other embodiments, the lamp board 2 and power supply 5, which are fixed by welding, can be replaced by an assembly 25 of long and short circuit boards carrying a power supply component 250. The assembly 25 has a long circuit board 251 and a short circuit board 253, which are attached to each other by adhesive bonding. The short circuit board 253 is located near the periphery of the long circuit board 251. The power supply component 25 is mounted on the short circuit board 253, forming a power supply unit. The long circuit board 251 can be the flexible circuit board or flexible substrate used as the lamp board 2, and the short circuit board 253 is made of a material that is harder than the long circuit board 251 to support the power supply component 250. The length of the short circuit board 253 is approximately 15 mm to 40 mm, preferably 19 mm to 36 mm, and the length of the long circuit board 251 can be 800 mm to 2800 mm, preferably 1200 mm to 2400 mm. The ratio of the short circuit board 253 to the long circuit board 251 can be 1:20 to 1:200.

[0154] The electrical connection between the circuit layer 2a of the lamp board 2 and the power supply assembly 250 can vary depending on the actual application. For example... Figure 35 As shown, the power supply assembly 250 and the long circuit board 251 (i.e., the circuit layer 2a of the lamp board 2) are both located on the same side of the short circuit board 253, and the power supply assembly 250 is directly electrically connected to the long circuit board 251. Figure 36 As shown, the power supply assembly 250 and the long circuit board 251 (i.e., the circuit layer 2a of the lamp board 2) are located on opposite sides of the short circuit board 253, respectively. The power supply assembly 250 is electrically connected through the short circuit board 253 and the circuit layer 2a of the lamp board 2. It should be noted that the assembly 25 of the long and short circuit boards in this embodiment omits the soldering method used in the aforementioned embodiments to fix the lamp board 2 and the power supply 5. Instead, the long circuit board 251 and the short circuit board 253 are first bonded together, and then the power supply assembly 250 is electrically connected to the circuit layer 2a of the lamp board 2. Furthermore, the lamp board 2, as described above, is not limited to one or two circuit boards. The light source 202 is located on the circuit layer 2a and is electrically connected to the power supply 5 through the circuit layer 2a.

[0155] In another embodiment, the long and short circuit board assembly 25 has a long circuit board 251 and a short circuit board 253. The long circuit board 251 can be the flexible circuit board or flexible substrate of the lamp board 2. The lamp board 2 includes a circuit layer 2a and a dielectric layer 2b. The dielectric layer 2b and the short circuit board 253 are first fixed together in a splicing manner. Then, the circuit layer 2a is attached to the dielectric layer 2b and extends to the short circuit board 253. This does not deviate from the application scope of the long and short circuit board assembly 25 of the present invention.

[0156] Please refer to Figure 37 In various embodiments of the present invention, the light source 202 can be further improved to include a bracket 202b with a groove 202a, and an LED chip (or dies) 18 disposed in the groove 202a. The groove 202a is filled with phosphor, which covers the LED chip (or die) 18 to achieve light color conversion. It should be noted that, compared with the traditional square shape of LED chips (or dies) with a length-to-width ratio of approximately 1:1, the length-to-width ratio of the LED chips (or dies) 18 used in various embodiments of the present invention can range from 2:1 to 10:1. The length-to-width ratio range of the LED chips (or dies) 18 used in various embodiments of the present invention is preferably from 2.5:1 to 5:1, and the optimal range is from 3:1 to 4.5:1. In this way, the length direction of the LED chips (or dies) 18 is arranged along the length direction of the lamp tube 1, which improves the average current density of the LED chips (or dies) 18 and the overall light output shape of the lamp tube 1.

[0157] It should be noted that in other embodiments, for the same LED straight tube light, only one or more of the following technical features may be included: "the lamp board adopts a flexible circuit board," "the inner circumferential surface of the lamp tube is coated with an adhesive film," "the inner circumferential surface of the lamp tube is coated with a diffusion layer," "the light source is covered with a diffusion film," "the light source has a bracket," and "the power supply has an assembly of long and short circuit boards." Specifically, the content regarding "the lamp board adopts a flexible circuit board" can be selected from one or a combination of the relevant technical features in the embodiments; the content regarding "the inner circumferential surface of the lamp tube is coated with an adhesive film" can be selected from one or a combination of the relevant technical features in the embodiments; the content regarding "the inner circumferential surface of the lamp tube is coated with a diffusion layer" can be selected from one or a combination of the relevant technical features in the embodiments; and the content regarding "the light source has a bracket" can be selected from one or a combination of the relevant technical features in the embodiments.

[0158] In lamp panels employing flexible circuit boards, the flexible circuit board is connected to the output terminal of the power supply via wire bonding or soldering. Furthermore, the flexible circuit board comprises a stack of a dielectric layer and a circuit layer; the flexible circuit board can be coated with a circuit protection layer of ink material, and the reflective film function can be achieved by increasing its circumferential width.

[0159] In the diffusion layer coated on the inner circumferential surface of the lamp tube, the components of the diffusion coating include at least one of calcium carbonate, calcium halophosphate, and alumina, as well as a thickener and ceramic activated carbon. Alternatively, the diffusion layer may be a diffusion film covering the light source.

[0160] In lamp holder design, the lamp holder may include an insulating tube and a heat-conducting part, wherein hot melt adhesive may fill part or completely of the accommodating space. Alternatively, the lamp holder may include an insulating tube and a magnetically conductive metal component, wherein the magnetically conductive metal component may be circular or non-circular, and the contact area with the insulating tube may be reduced by providing a perforated structure or an indented structure. Furthermore, the insulating tube may also incorporate support parts or protrusions to enhance support for the magnetically conductive metal component and reduce the contact area between the magnetically conductive metal component and the insulating tube.

[0161] In power supply design, a combination of long and short circuit boards consists of a long circuit board and a short circuit board, which are attached to each other and fixed by adhesive. The short circuit board is located near the periphery of the long circuit board. The power supply components are located on the short circuit board, and the whole assembly constitutes the power supply.

[0162] In other words, the above features can be arranged and combined in any way and used to improve LED straight tube lights.

Claims

1. An LED straight tube lamp, characterized in that, include: A lamp tube, the lamp tube including a diffusion coating covering the inner circumferential surface of the lamp tube, the lamp tube being a glass lamp tube; Two lamp holders are respectively located at both ends of the lamp tube. Each lamp holder has holes for heat dissipation and a hollow conductive needle. The two lamp holders are the same size. A lamp panel, disposed inside the lamp tube, is provided with a light source; and A power supply, which is electrically connected to the light source through the lamp board, the power supply includes a circuit board and a power module disposed on the circuit board, wherein the power supply is disposed in at least one of the two lamp heads; The lamp board is a flexible circuit board or a flexible substrate. The lamp board has a portion fixed to the inner circumferential surface of the lamp tube and portions located at both ends of the lamp board that are not fixed to the inner circumferential surface of the lamp tube. The portions not fixed to the inner circumferential surface of the lamp tube form free portions. One end of the free portion contracts and deforms into the lamp tube, and the free portion is directly soldered to the circuit board of the power supply. The free portion is an integral part of the flexible circuit board or flexible substrate.

2. The LED straight tube light according to claim 1, characterized in that, The lamp panel includes a conductive circuit layer, and the light source is disposed on the circuit layer and electrically connected to the power supply through the circuit layer.

3. The LED straight tube light according to claim 1, characterized in that, The length of the lamp panel is greater than the length of the lamp tube.

4. The LED straight tube light according to claim 1, characterized in that, The circuit board is a rigid circuit board to support the power module.

5. The LED straight tube light according to claim 2, characterized in that, The power module and the lamp board are located on opposite sides of the circuit board, and the power module is electrically connected through the circuit layers of the circuit board and the lamp board.

6. The LED straight tube light according to claim 2, characterized in that, The power module and the lamp board are both located on the same side surface of the circuit board, and the power module is directly electrically connected to the lamp board.

7. The LED straight tube light according to claim 1, characterized in that, The power supply has a power pad, and the end of the lamp board has a light source pad, and the power pad and the light source pad are soldered together.

8. The LED straight tube light according to claim 7, characterized in that, The light source pads and the plane containing the light source on the lamp board face the same direction.

9. The LED straight tube light according to claim 7, characterized in that, The light source pads have 3, and the number of power supply pads is the same as the number of light source pads.

10. The LED straight tube lamp according to claim 9, characterized in that, The light source pads are arranged in a row.

11. The LED straight tube light according to claim 1, characterized in that, The material of the circuit board is harder than the material of the lamp board.

12. The LED straight tube light according to claim 1, characterized in that, The lamp holder is a metal lamp holder, and an insulator is provided at the lower part of the hollow conductive needle.

13. The LED straight tube lamp according to claim 1, characterized in that, The diffusion coating comprises any one of calcium carbonate, calcium halophosphate, and alumina, or a combination of any two or three of them.

14. The LED straight tube light according to claim 1, characterized in that, The diffusion coating consists of calcium carbonate and strontium phosphate.

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