LED Tube Lamp PCB Layout for Wire-Free Assembly and Heat Dissipation
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Solution Overview
Problem
Existing LED tube lamps face issues with wire damage during manufacturing, transportation, and usage, and inadequate heat dissipation of the driving module, leading to reduced lifespan and performance.
Innovation Solution
The LED tube lamp design includes a glass lamp tube with an LED light strip adhered to its inner surface, a power supply module with a circuit board parallel to the tube axis, and a diffusion layer covering the outer surface, along with a protective layer allowing for efficient heat dissipation and protection of LED light sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires are used to connect power supply to light sources, then electrical connection is achieved, but wires are easily damaged and broken during manufacturing, transportation, and usage
Solution Approach 1:
The patent removes the vulnerable wire connection from the system by using a rigid PCB board to establish electrical connections between the power supply module and LED light sources. The PCB serves as a stable, damage-resistant alternative to flexible wires, eliminating the reliability issue while maintaining electrical connectivity.
Solution Approach 2:
The patent introduces a PCB board as an intermediary component between the power supply and LED lights. This mediator provides a rigid, stable connection structure that replaces the fragile wire, solving the durability problem while enabling reliable electrical transmission throughout the lamp system.
2Area of stationary object
If driving module is placed close to LED light sources, then space is saved, but heat generated by driving module affects LED light sources
Solution Approach 1:
The patent divides the internal space of the lamp tube into distinct functional zones: one region for the LED light sources and another region for the driving module. This spatial segmentation allows heat generated by the driving module to be isolated from the LED lights, preventing temperature interference while utilizing the available space efficiently.
Solution Approach 2:
The patent applies different thermal management characteristics to different regions within the lamp tube. The area surrounding the LED light sources is designed with heat dissipation considerations, while the driving module region accommodates heat generation. This local differentiation of thermal properties ensures LED performance is not degraded by driving module heat.
3Reliability
If end cap with male and female terminals is used for electrical connection, then connection is established, but it is difficult to sleeve end cap over end of lamp tube
Solution Approach 1:
The patent removes the complex male-female terminal connection mechanism from the end cap assembly. Instead, electrical connections are established through the PCB board that extends into the end cap, eliminating the need for separate terminal mating operations and simplifying the assembly process while maintaining reliable electrical connectivity.
Solution Approach 2:
The patent combines the electrical connection function and the mechanical support function into a single integrated PCB structure. The PCB serves both as the electrical pathway and as the structural element that positions components, eliminating the need for separate terminal components and simplifying the overall assembly process.
Data Source
AI summary
An LED tube lamp comprises a glass lamp tube having a main body, two end caps coupled to a respective end of the tube, an LED light strip adhered to inner circumferential surface of the tube by first adhesive, a plurality of LED light sources mounted on a mounting region, a power supply module having a circuit board and a plurality of electronic components mounted on the circuit board, a diffusion layer covering on outer surface or inner surface of the tube, and a protective layer being disposed on surface of the strip and having a plurality of first openings for disposing the plurality of LED light sources. The strip comprises the mounting region and connecting region at an end of the strip. The circuit board is substantially parallel with axial direction of the tube, electrically connects to the connecting region, and stacks with a portion of the connecting region.