Leadframe Stabilizing Sections for Tube Lamp Housing Adhesion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of LED retrofit tube lamps faces high costs and environmental pollution due to the use of copper in printed circuit boards and carrier materials, and existing leadframe solutions require additional components and processing steps for stabilization and fastening.
Innovation Solution
A method using a leadframe with stabilizing sections made from electrically insulating materials, which are applied to connect and stabilize the leadframe elements, allowing for adhesion to the tubular housing without additional retaining clips or processing steps, using materials like thermoplastic or glass for the stabilizing sections and coatings such as Sn, Zn, Au, Ag, Pt, Pd, or Ni on the leadframe surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If printed circuit boards with copper coating are used for the light engine, then electrical conductivity and structural stability are ensured, but material consumption increases and production costs rise along with environmental pollution
Solution Approach 1:
The patent extracts and removes the copper coating from the printed circuit board, retaining only the essential electrical conductive tracks made from the base material itself. This eliminates the need for additional copper material while preserving the electrical conductivity function through the inherent conductive properties of the leadframe material.
Solution Approach 2:
The leadframe structure serves multiple functions simultaneously: it provides structural support for the LEDs, creates the electrical conductive paths, and acts as the mounting substrate. This multi-functionality eliminates the need for separate copper coatings and complex PCB structures, reducing material consumption while maintaining reliability.
2Loss of substance
If leadframes without stabilizing sections are used, then material consumption is reduced, but the leadframe lacks sufficient stability and requires additional retaining clips and fastening steps
Solution Approach 1:
The leadframe is segmented into functional sections including stabilizing sections with protrusions that extend from the main body. These segmented stabilizing elements provide targeted structural support and positioning functionality without requiring additional fastening components, maintaining stability while minimizing material usage.
Solution Approach 2:
The leadframe's own structure is designed to provide stabilization through integrated stabilizing sections with protrusions. These self-contained features perform the stabilizing function that would otherwise require separate retaining clips or additional fastening components, eliminating the need for extra parts and processing steps.
3Stability of the object's composition
If additional retaining clips and fastening components are used to stabilize the leadframe, then structural stability is improved, but device complexity and processing steps increase
Solution Approach 1:
The stabilizing sections are merged directly into the leadframe structure itself, combining the functions of structural support, positioning, and stabilization into a single integrated component. This eliminates the need for separate retaining clips and fastening components, reducing device complexity while maintaining leadframe stability.
Solution Approach 2:
The leadframe structure is designed to perform multiple functions including structural support, electrical conduction, and self-stabilization through integrated stabilizing sections. This multi-functionality eliminates the need for additional specialized fastening components, reducing the total number of parts and simplifying the overall device complexity.
4Strength
If thick carrier materials with fabric stabilization are used, then structural strength is ensured, but production costs and material consumption increase
Solution Approach 1:
The patent extracts and eliminates the thick carrier material and fabric stabilization layers, retaining only the essential leadframe structure. The stabilizing sections with protrusions provide the necessary structural strength and positioning functionality without requiring excessive material thickness or additional fabric impregnation layers.
Solution Approach 2:
The leadframe geometry is optimized with specifically designed stabilizing sections and protrusions that provide adequate structural strength through shape and configuration rather than material thickness. This parameter change from thickness-based strength to geometry-based strength reduces material consumption while maintaining structural integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces material consumption, simplifies the production process, and ensures stable adhesion of the leadframe to the housing, enhancing light uniformity and reducing environmental impact while eliminating the need for additional fastening components.
Implementation Method 1
the stabilizing sections (at least the stabilizing sections which are intended to serve for fastening the leadframe in the tubular housing) are heated to a temperature at which the stabilizing sections are molten
Implementation Method 2
heated to a temperature at which the stabilizing sections are molten
Implementation Method 3
the leadframe is adhered to the tubular housing, wherein the material of the molten stabilizing sections is connected to the tubular housing by non-positive engagement
Implementation Method 4
The surfaces of the leadframe can also be coated with a good reflecting coating, for example with a white or light colour or lacquer layer (in particular solder resist)
Data Source
AI summary
A method for producing a tube lamp uses at least one leadframe. A leadframe is a flat structure which has two opposing surfaces extending substantially parallel and spaced apart by the sheet thickness. One or more stabilizing sections are applied to the leadframe. The leadframe is fastened with the stabilizing sections in a tubular housing of the tube lamp.