Retractable LED Tube End-Cap with Rotatable Pins
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Solution Overview
Problem
Existing LED tube end-caps pose electrical shock hazards during installation and fail to accommodate fixtures of varying lengths, leading to poor connections and installation difficulties.
Innovation Solution
A retractable and rotatable end-cap design with an elastic component and interlocking mechanism that connects power pins only when both ends are inserted, allowing for adjustable length and safe installation, while enabling independent assembly and modular manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an extruded spring-based safety switch is used on the end-cap, then electrical safety during installation is improved, but connection reliability deteriorates when the lamp-holder loosens over time
Solution Approach 1:
The patent employs a dynamic connection mechanism where the power connector is spring-loaded to maintain constant contact pressure with the power pin. This dynamic adjustment compensates for lamp-holder loosening over time, ensuring reliable electrical connection while maintaining safety through the retractable design that keeps bi-pins disconnected during installation.
Solution Approach 2:
The spring-loaded power connector automatically adjusts its contact pressure based on the lamp-holder's condition. When the lamp-holder loosens, the spring mechanism self-adjusts to maintain proper electrical contact without requiring manual intervention, thereby maintaining connection reliability throughout the product lifecycle.
2Object-affected harmful factors
If an extruded spring-based safety switch is used on the end-cap, then electrical safety during installation is improved, but adaptability to fixtures of varying lengths deteriorates
Solution Approach 1:
The retractable end-cap design incorporates a dynamic extension mechanism that allows the bi-pins to extend only when both ends are properly inserted into the fixture. This dynamic behavior enables the LED tube to adapt to fixtures of varying lengths while maintaining electrical safety during the installation process, as the bi-pins remain retracted until proper installation is achieved.
3Reliability
If a spring-based floating end-cap is used, then connection reliability is improved, but ease of operation deteriorates due to difficulty in aligning hidden bi-pins
Solution Approach 1:
The patent incorporates visual indicators (such as colored markings or transparent sections) on the end-cap housing that reveal the position and orientation of the hidden bi-pins. This visual feedback mechanism guides the installer in proper alignment during installation, significantly improving ease of operation while maintaining the reliability benefits of the spring-based floating end-cap design.
4Reliability
If a spring-based floating end-cap is used, then connection reliability is improved, but device complexity increases due to the floating mechanism
Solution Approach 1:
The patent divides the end-cap into separate functional modules: the floating housing mechanism, the spring-loaded power connector, and the bi-pin assembly. This segmentation allows each component to be optimized independently and simplifies manufacturing and assembly processes, reducing overall device complexity while maintaining the reliability benefits of the floating design.
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 prevents electrical shocks, ensures secure connections, and allows for flexible length adjustment, enhancing safety and usability, but requires piece-by-piece assembly and fixed light direction, which limits applications.
Implementation Method 1
an elastic component disposed between the power-pin assembly and the end-cap base assembly
Data Source
AI summary
Embodiments of an end-cap with retractable and rotatable pin for an LED tube are described. In one aspect, an end-cap for an LED tube may include an end-cap housing, an end-cap base assembly, a power-pin assembly, and at least one elastic component. The power-pin assembly may include at least one power pin thereon and configured to connect to an external power source. The power-pin assembly may protrude out of a center opening of the end-cap housing. The end-cap base assembly may have at least one power connector one end of which is connected to the body of the LED tube to receive electric power. The at least one elastic components may reside inside the end-cap housing and is placed between the power-pin assembly and the end-cap base assembly. The power connector may connect to the at least one power pin when the at least one elastic component is pressed.