LED Tube Driver Fixation Using Expanded Adhesive
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing light fixtures with tubular housings face challenges in cost-effective production and reliable fixation of driver devices due to complex and expensive end caps and adhesives, leading to potential loose connections and increased manufacturing costs.
Innovation Solution
A light fixture design utilizing a light-permeable tube with end caps fastened using an expanded adhesive, which also secures the driver device, eliminating the need for separate guide tracks and additional adhesives, and allowing for a single heat application step, thereby simplifying production and ensuring a secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plastic end caps with guide tracks are used to fix the driver device, then the driver device can be held in position, but the production complexity and cost increase due to separate injection molding processes
Solution Approach 1:
The patent combines the driver device fixation function with the end cap structure by applying adhesive directly to the end cap's inner surface, eliminating the need for separate guide tracks. This merging of functions simplifies the end cap structure while maintaining reliable driver device fixation.
Solution Approach 2:
The patent extracts the guide track component from the end cap structure and replaces it with a simpler adhesive bonding system. By removing the complex guide track feature, the end cap can be produced as a simple metal shaped part without separate injection molding processes.
2Reliability
If adhesive is used to fix the driver device on the end cap, then fixation is achieved, but additional expensive bonding adhesive is required
Solution Approach 1:
The patent merges the function of the structural adhesive (for bonding end cap to tube) with the fixation adhesive (for securing driver device). A single adhesive application serves both purposes, eliminating the need for separate bonding adhesive and reducing material costs.
Solution Approach 2:
The adhesive applied to the end cap performs multiple functions: it bonds the end cap to the tube and simultaneously fixes the driver device in position. This multi-functional approach eliminates the need for separate adhesive materials and application steps.
3Ease of manufacture
If metallic end caps with base sleeves are used, then the driver device can be inserted, but the driver device can become loose and knock against the tube wall
Solution Approach 1:
The patent replaces the mechanical base sleeve insertion system with an adhesive bonding system. The adhesive provides continuous contact and bonding between the driver device and the end cap, preventing loosening and knocking against the tube wall while maintaining ease of assembly.
4Manufacturing precision
If separate adhesive application steps are used for end cap and driver device fixation, then precise fixation is achieved, but manufacturing time and complexity increase
Solution Approach 1:
The patent combines multiple adhesive application steps into a single operation. The adhesive is applied once to the end cap, and upon curing, it simultaneously bonds the end cap to the tube and fixes the driver device, reducing manufacturing time while maintaining precise fixation.
Solution Approach 2:
The adhesive is applied in advance to the end cap before final assembly, allowing it to cure and provide strong bonding. This preliminary application ensures precise fixation is achieved without requiring multiple subsequent adjustment steps, thereby improving production efficiency.
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
The solution reduces production costs, enhances the reliability of the driver device's fixation, and simplifies the manufacturing process while maintaining a sturdy and secure connection, eliminating the need for expensive adhesives and complex production steps.
Implementation Method 1
the end cap is fastened on the tube by means of an expanded adhesive
Implementation Method 2
a heat-curing cement, which is applied to the inner face of a cylindrical collar of the end cap
Data Source
AI summary
A light fixture and a method of making a light fixture include a light-permeable tube, at least one end cap pushed onto a free end of the tube for closure, and a driver device received at least partially in the tube and held in the tube by the end cap for driving a light module arranged in the tube. The end cap is fastened on the tube by an expanded adhesive and the driver device is fastened to the end cap or to the tube by the expanded adhesive.