Retrofittable LED Tube Lamp Modular Core Assembly
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Solution Overview
Problem
Current linear LED tube lamps are not easily retrofittable, leading to unnecessary waste and safety hazards during driver replacement, as the internal LED driver is either not mechanically secured or difficult to replace, resulting in whole lamp disposal rather than component-level upgrades, which is not eco-friendly and fails to meet evolving energy standards.
Innovation Solution
A modular structure with an elongated housing, LED PCB, electronic control units, and lamp bases with secure core assemblies allows for easy replacement of the LED driver without disassembling the lamp, using pluggable wires and insulated connections to prevent electric shock, enabling cost-effective upgrades and reuse of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the LED driver is not mechanically secured in the lamp housing, then it is easy to replace, but the lamp becomes unsafe due to potential electric shock hazards from exposed conductors
Solution Approach 1:
The patent introduces an intermediate core assembly that serves as a mediator between the lamp housing and LED driver. This core assembly includes insulating structures and secured conductor pathways that isolate live electrical components from the housing, allowing the driver to be mechanically secured yet easily replaceable through a standardized interface without exposing users to electric shock hazards.
Solution Approach 2:
The patent segments the lamp into distinct modular components: the housing, the core assembly (containing electrical connections), and the LED driver. This segmentation allows the driver to be independently secured to the core assembly with simple mechanical fasteners, enabling easy replacement while the core assembly remains fixed to the housing to maintain safety isolation.
2Object-affected harmful factors
If the LED driver is mechanically secured with complex fastening mechanisms, then safety is improved, but ease of replacement deteriorates
Solution Approach 1:
The patent divides the securing function into two parts: the core assembly is permanently secured to the housing through insulating structures, while the LED driver is attached to the core assembly using simple removable fasteners. This segmentation allows different levels of securing complexity for different components based on their functional requirements.
Solution Approach 2:
The core assembly acts as an intermediary that provides a standardized mounting interface for the LED driver. This intermediate structure with pre-configured insulating barriers and simple fastener points enables safe yet easy replacement without requiring complex securing mechanisms.
3Reliability
If wire connections are soldered directly to the LED driver, then electrical connection reliability is improved, but ease of repair and component replacement deteriorates
Solution Approach 1:
The patent segments the electrical connection system into permanent soldered joints within the core assembly and removable connector interfaces for the LED driver. This allows reliable internal connections while maintaining ease of external component replacement through standardized electrical connectors.
Data Source
AI summary
A linear light-emitting diode (LED) tube lamp having a readily retrofittable modular structure enables consumers or manufacturers to readily retrofit the lamp by replacing an LED module or internal electronic control units that include an LED driver in maintenance or lamp upgrade without hazards. The readily retrofittable modular structure includes a core assembly in each of lamp bases for easily securing or removing the electronic control unit through a mechanical securing means, and two sets of connection modules for quickly connecting and disconnecting the electronic control unit with the LED module. The readily retrofittable modular structure may use one bi-pin or two bi-pins to connect to the AC mains via pluggable wire for delivering power to the LEDs. Thus, the LLT lamp using the readily retrofittable modular structure may be configured as single-ended, double-ended, or double-ended with double shock-protection switches and can be cost-effectively retrofitted after initial installation.