Integrated LED Lamp Base with Parallel Tube Segments
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Solution Overview
Problem
Existing LED plug-in tube lamps have complex assembly processes, high production costs, and low efficiency due to their large weight and shape, making them unsuitable replacements for fluorescent lamps.
Innovation Solution
A new LED lamp design featuring a tubular structure with parallel segments, a light source assembly, and a drive assembly, where the light source is thermally connected to the lamp tube, and electrically connected to the drive assembly via terminals, with a simplified assembly process facilitated by a lamp base fixture and ultrasonic welding, reducing weight and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional LED plug-in tube lamps are used to replace fluorescent lamps, then energy consumption is reduced, but the assembly process becomes complicated and production cost increases
Solution Approach 1:
The patent integrates the drive assembly directly into the lamp base structure, merging previously separate components (lamp base, drive assembly, and mounting structure) into a unified integrated base. This integration eliminates the need for separate mounting brackets and complex assembly steps, directly resolving the contradiction between energy efficiency and assembly complexity
Solution Approach 2:
The lamp base is designed with multi-functionality, serving both as the structural support for the lamp tube and as the housing for the drive assembly. The base simultaneously provides electrical connection terminals, mechanical mounting features, and structural support, thereby simplifying the overall assembly process while maintaining energy efficiency
2Use of energy by moving object
If traditional LED plug-in tube lamps are used to replace fluorescent lamps, then energy consumption is reduced, but production cost increases
Solution Approach 1:
By merging the drive assembly into the lamp base structure, the patent reduces the total number of components that need to be manufactured, stored, and assembled. This integration simplifies the supply chain and manufacturing process, directly addressing the production cost increase while maintaining energy efficiency benefits
Solution Approach 2:
The lamp is divided into clearly defined functional segments (lamp base with integrated drive assembly, lamp tube with light source, and connecting fixtures) that can be manufactured independently using standardized processes. This segmentation enables parallel production and assembly, reducing overall manufacturing complexity and cost
3Use of energy by moving object
If traditional LED plug-in tube lamps are used to replace fluorescent lamps, then energy consumption is reduced, but assembly efficiency decreases
Solution Approach 1:
The integration of the drive assembly into the lamp base creates a pre-assembled unit that requires fewer assembly steps when installing the complete lamp. This merging eliminates intermediate assembly operations and reduces the time required for production assembly, directly improving productivity while maintaining energy efficiency
Solution Approach 2:
The drive assembly is pre-integrated into the lamp base during manufacturing, creating a ready-to-install unit. This preliminary action of pre-assembly eliminates the need for on-site assembly of multiple separate components, significantly improving assembly efficiency in production environments
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 design simplifies the assembly process, reduces production costs, enhances heat dissipation, and meets the structural requirements of fluorescent lamps, making it a more efficient and cost-effective replacement.
Implementation Method 1
With the development and popularization of LED light sources, traditional incandescent lamps and fluorescent lamps are gradually replaced by LED lamps
Implementation Method 2
The lamp tube has a flat bottom structure on one side, and the first ribs are disposed on both sides of the flat bottom structure to fit a surface of the light source assembly without light bead to the flat bottom structure
Data Source
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AI summary
A lamp is disclosed in the present disclosure, and includes a lamp tube (1), a light source assembly (2), a drive assembly (3) and a lamp base (4), the lamp tube (1) has tubular structure and has at least two segments (11) arranged in parallel with each other, the light source assembly (2) is arranged extending at least within the segment (11), the light source assembly (2) and the drive assembly (3) are electrically connected to each other, the drive assembly (3) is mounted fixed inside the lamp base (4). The lamp can meet the requirements of fluorescent lamp in terms of structural appearance and can replace fluorescent lamp. The lamp has the advantages of low weight, simple assembly, simple process flow, high production efficiency, high heat dissipation efficiency and low production cost.