External Electrode Fluorescent Lamp Inner Cap Mechanical Lead Retention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing external electrode fluorescent lamps (EEFLs) in backlight modules have reliability issues due to time-consuming soldering of conductive wires and a high likelihood of these wires falling off during normal use, affecting the overall performance and reliability of the EEFL and the backlight module.
Innovation Solution
The EEFL design features two electrodes fixed at its ends with inner caps that include a conductive layer and a lead receiving portion, allowing for secure electrical connection without soldering, using a hermetically-sealed fluorescent tube with deformable and insulated inner caps and screw-threaded engagement for reliable assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering method is used to connect conductive wires to electrodes, then electrical connection is achieved, but assembly time increases and reliability decreases due to wires falling off
Solution Approach 1:
The patent extracts the soldering process from the assembly method and replaces it with a mechanical insertion structure. The inner cap with lead receiving portion allows direct insertion of conductive leads without soldering, eliminating the time-consuming and unreliable soldering step while maintaining electrical connection.
Solution Approach 2:
The inner cap serves as an intermediary component between the electrode and the conductive lead. It provides a lead receiving portion that mechanically holds the lead and ensures electrical contact, acting as a mediator that eliminates the need for direct soldering between wire and electrode.
2Ease of manufacture
If soldering is used to connect conductive wires, then electrical connection is established, but the complexity of manufacturing increases due to soldering requirements
Solution Approach 1:
The patent removes the soldering operation from the manufacturing process by designing a mechanical insertion system. The inner cap's lead receiving portion provides a simple insert-and-lock mechanism that eliminates complex soldering equipment and procedures.
Solution Approach 2:
The inner cap structure is designed to automatically secure the conductive lead through its lead receiving portion and engagement features. The deformable nature of the inner cap allows it to self-adjust and secure the lead without external intervention or complex assembly tools.
3Reliability
If conductive wires are soldered to electrodes, then electrical connection is achieved, but the wires are liable to fall off during normal use reducing reliability
Solution Approach 1:
The patent extracts the weak soldered connection and replaces it with a mechanical retention system. The lead receiving portion of the inner cap provides positive mechanical engagement that prevents the conductive lead from detaching during normal operation, offering superior connection strength.
Solution Approach 2:
The conductive lead is nested within the lead receiving portion of the inner cap, which is itself nested around the electrode. This nested structure provides multiple levels of mechanical retention and electrical contact, ensuring the connection remains secure during normal use.
Data Source
AI summary
An exemplary external electrode fluorescent lamp includes a fluorescent tube having two electrodes fixed at two ends thereof, and two inner caps respectively holding the electrodes. Each inner cap includes an electrode receiving portion configured for receiving the electrode, a conductive layer provided at inner surfaces of the electrode receiving portion, a lead receiving portion integrally formed with the electrode receiving portion, and a conductive lead received in the lead receiving portion. The conductive layer contacts the conductive layer. A backlight module employing the external electrode fluorescent lamp is also provided.