Spliced Light Source Module Assembly for Custom Tube Lengths

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Solution Overview

Problem

Current light source boards for tube lights are limited in length, requiring expensive large-scale equipment for customization, leading to increased manufacturing costs for longer lengths such as 1.8 meters or 2.4 meters.

Innovation Solution

A method for manufacturing high-reliability light source modules by segmenting a circuit board into sub-boards, installing light sources, splicing the sub-boards, and soldering connectors, allowing for the production of boards of various lengths without large equipment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If light source boards are manufactured in standard lengths (0.6m, 1.2m, 1.5m), then manufacturing cost is reduced, but customization for longer lengths (1.8m, 2.4m) requires expensive large-scale equipment

Engineering Contradiction:

Improvemanufacturing costVSAvoidcustomization capability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The light source board is divided into multiple sub-boards (first sub-board, second sub-board, etc.) that can be manufactured separately using standard equipment, then connected together to form longer customized boards. This resolves the contradiction by enabling customization without requiring expensive large-scale equipment for entire long boards.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple sub-boards are nested or connected in sequence to form longer light source boards. The sub-boards contain solder pads and connectors that interface with each other, allowing standard-length components to be assembled into customized longer configurations.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If light source boards are segmented into sub-boards and connected, then customization for different lengths is enabled, but connection reliability may be compromised

Engineering Contradiction:

Improvecustomization capabilityVSAvoidconnection reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

Solder pads are pre-formed on the sub-boards during manufacturing, and connectors are pre-positioned. This preliminary preparation ensures that when sub-boards are connected, the electrical connections are already optimized for reliability, reducing the risk of connection failures.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Connectors serve as intermediary elements between sub-boards, providing reliable electrical connection. The connectors are designed with bending regions that can accommodate mechanical stress, protecting the solder joints and maintaining connection reliability during assembly and operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If connectors are made rigid for stable connection, then connection stability is improved, but susceptibility to damage during assembly and transportation increases

Engineering Contradiction:

Improveconnection stabilityVSAvoidsusceptibility to damage

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The connectors incorporate bending regions with curved portions instead of rigid straight structures. These curved sections can flex and absorb mechanical stress during assembly and transportation, protecting the connection while maintaining electrical stability. The curvature allows the connector to deform elastically under stress rather than fracturing.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The bending regions are designed in advance to provide cushioning against mechanical stress. The curved portions act as built-in shock absorbers that protect the connector and solder joints from damage during handling, assembly, and transportation, eliminating the need for external protective measures.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 method reduces manufacturing costs by enabling the production of light source boards of different lengths through simple steps, improving the reliability and service life of lighting devices by using bending regions and protrusion portions as buffering structures.

Implementation Method 1

soldering one end of a first connector on the positive solder pad of the first sub-circuit board; soldering the other end of the first connector on the positive solder pad of the second sub-circuit board

Methodology Applied

Scientific EffectSoldering: Soldering

Data Source

PatentUS20250143013A1Method for manufacturing high-reliability light source module

Publication Date: 2025.05.01 XIAMEN PVTECH CO LTD

AI summary

A method for manufacturing high-reliability light source module includes the following steps: segmenting a circuit board into a first sub-circuit board and a second sub-circuit board; installing a plurality of light sources on the first sub-circuit board and the second sub-circuit board; placing the first and second sub-circuit boards on a section bar; splicing the first sub-circuit board with the second sub-circuit board, and aligning the positive and negative solder pads of the first sub-circuit board with the positive and negative solder pads of the second sub-circuit board; soldering the two ends of a first connector on the positive solder pad of the first sub-circuit board and the positive solder pad of the second sub-circuit board respectively; soldering one end of a second connector on the negative solder pad of the first sub-circuit board and the negative solder pad of the second sub-circuit board respectively.