LED Base Module Supporting Base Avoids Pin Deformation
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Solution Overview
Problem
The existing manufacturing process for LED lighting strips faces issues with pseudo soldering, insecure soldering, and pin deformation due to the direct soldering and cutting of power and signal lines on the LED frame, leading to a high failure rate and low reliability.
Innovation Solution
The introduction of an LED base module with a supporting base that includes conductive portions and avoidance through-holes allows for soldering and stamp-cutting of conductive lines on the supporting base, avoiding direct contact with the LED lighting base, thus preventing pseudo soldering and pin deformation, and enhancing processing efficiency and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If power line and signal line are directly soldered to pins on LED frame, then manufacturing process is simple, but pseudo soldering and insecure soldering occur frequently
Solution Approach 1:
The patent introduces a supporting base as an intermediary component between the LED frame and the conductive lines. The supporting base provides a dedicated soldering area with conductive portions that receive the power line and signal line, preventing direct soldering to the LED frame pins. This intermediary structure eliminates pseudo soldering and insecure soldering issues while maintaining manufacturing simplicity.
Solution Approach 2:
The patent segments the soldering function from the LED frame structure by creating a separate supporting base. The supporting base is divided into conductive portions for soldering and non-conductive portions for support, allowing independent optimization of each function. This segmentation enables reliable soldering without compromising the LED frame structure.
2Ease of operation
If signal line is cut off between pins to form signal input line and signal transmission line, then signal routing is achieved, but pin deformation occurs frequently
Solution Approach 1:
The supporting base serves as an intermediary that receives conductive lines after they pass through avoidance through-holes. By providing a dedicated receiving area on the supporting base, the patent prevents stamp-cutting operations from contacting the LED frame pins, thereby eliminating pin deformation while maintaining signal routing capability.
Solution Approach 2:
The patent moves the stamp-cutting operation to a different spatial dimension by routing conductive lines through avoidance through-holes in the supporting base. This three-dimensional arrangement separates the cutting process from the pin location, allowing signal routing without pin deformation.
3Productivity
If soldering and stamp-cutting are performed on LED lighting base, then direct connection is achieved, but processing defects increase
Solution Approach 1:
The supporting base acts as an intermediary platform that concentrates all soldering and stamp-cutting operations on its conductive portions and avoidance through-holes. This separates the processing activities from the LED lighting base, preventing defects on the LED components while maintaining processing efficiency.
Data Source
AI summary
An LED base module includes an LED lighting base and a supporting base. The LED lighting base includes an insulation housing and multiple conductive terminals fixed in the insulation housing. Each of the conductive terminals includes a chip fixing portion electrically connected to the chip assembly and a pin portion exposed outside the insulation housing. The supporting base includes multiple conductive portions and one or more avoidance through-holes. Each of the conductive portions includes a first terminal portion and a second terminal portion which are respectively exposed at two opposite surfaces of the supporting base. The first terminal portion is electrically connected to the pin portion, and the second terminal portion is electrically connected to a conductive line. The avoidance through-hole is provided for avoidance of stamp-cutting of one of the conductive lines.