LED Light Tube End Cap with Self-Docking Driver Board
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Solution Overview
Problem
Prior LED light tube driver and end cap arrangements lack simplicity, strength, ease of replacement, and flexibility for replacing malfunctioning driver boards or retrofitting for different communication and networking capabilities.
Innovation Solution
A separate LED driver board is integrated with the end cap, forming a snap-connection to the LED board and tube, providing a multi-level structural bridge with spring-biased power supply terminals and a connector tongue for secure alignment and easy assembly, allowing for wireless communication and indicator lights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the driver board is soldered or connected by wire-and-plug terminals between the end cap and LED board, then the electrical connection is established, but the replacement and modification becomes complex and time-consuming
Solution Approach 1:
The driver board is designed as a separate, modular component that can be independently removed and replaced. The end cap is segmented to accommodate the driver board as a distinct assembly, allowing the driver board to be swapped out without affecting the LED board or other components. This modular segmentation enables quick replacement while maintaining simple connections through the integrated end cap structure.
Solution Approach 2:
The driver board is merged with the end cap to form an integrated assembly. The end cap serves dual functions as both a structural closure and a mounting platform for the driver board. This merging eliminates the need for separate wire-and-plug connections between the end cap and driver board, simplifying the overall connection structure while enabling easy replacement of the entire driver board-end cap assembly.
2Strength
If the driver board is built into or connected directly to the end cap, then the structural strength is improved, but the flexibility for replacement and retrofitting is reduced
Solution Approach 1:
The driver board-end cap assembly is segmented as a removable unit that can be separated from the light tube. The end cap includes a removable structure that allows the driver board assembly to be detached and replaced with different configurations. This segmentation maintains strong structural connections during operation while enabling flexible replacement and retrofitting when needed.
Solution Approach 2:
The connection between the driver board-end cap assembly and the light tube is designed to be dynamic rather than permanent. The end cap incorporates removable features that allow the assembly to be easily installed and removed. This dynamic connection provides structural strength during use while maintaining flexibility for replacement and adaptation to different driver board configurations.
3Ease of operation
If traditional driver board connections are used, then the basic functionality is achieved, but the ease of assembly and mechanical strength are insufficient
Solution Approach 1:
The driver board is merged with the end cap to form a single integrated assembly that is installed as one unit. The end cap structure incorporates mounting features for the driver board, eliminating the need for separate assembly steps. This merging simplifies the assembly process while the integrated structure provides enhanced mechanical strength compared to separate wire-and-plug connections.
Solution Approach 2:
The end cap structure includes self-aligning and self-securing features that automatically position and secure the driver board during assembly. The integrated design allows the driver board to be mounted to the end cap through the assembly process itself, without requiring additional fastening operations. This self-service approach enhances both ease of assembly and mechanical strength.
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 design enhances the simplicity, strength, and ease of replacement of driver boards while enabling flexible retrofitting of LED light tubes with improved mechanical and electrical connections, supporting wireless communication and networking capabilities.
Implementation Method 1
An upper, outer (cap-side) end surface of the driver board includes spring-biased power supply terminals that mechanically and electrically engage the upper surface of an outer end of the LED board
Implementation Method 2
The connector tongue includes a detent and guide cooperating with a slot and detent aperture on the light tube sidewall to align the driver and LED boards as the cap is applied
Data Source
AI summary
An LED light tube assembly comprising an LED light tube with an LED array board in a tubular housing, and an end cap with a driver board removably secured to the end of the LED light tube. The driver board extends from a cap midpoint at a first level corresponding to an underside of the LED board in the tube, and the cap includes a connector tongue spaced from and parallel to the driver board at a second level corresponding to a portion of the sidewall of the tubular housing. The driver board further includes spring terminals that frictionally engage an upper surface of the LED board as the cap is assembled to the light tube, while remaining assembly and connection forces are borne by the cap and the tubular housing.