Lamp Module Insulator Design for LED Safety
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Solution Overview
Problem
Conventional LED luminaries face safety issues due to conductive leads contacting metal barriers through insulator openings, and precise positioning of LEDs is challenging due to compact dimensions.
Innovation Solution
A lamp module design featuring a circuit board with an insulator having openings and protruding sheets to insulate conductive leads from metal barriers, with metal barriers covering the leads to prevent short circuits and simplify assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an insulator with openings is used to allow LEDs to pass through, then the LED can be mounted on the circuit board, but the conductive leads of the LED may contact the metal barrier through the openings causing safety issues
Solution Approach 1:
The patent introduces a second insulator positioned between the metal barrier and the first insulator to cover the conductive leads of the LED. This intermediary insulator prevents direct contact between the conductive leads and the metal barrier, thereby maintaining electrical insulation while allowing the LED to pass through the opening. The second insulator acts as a mediator that resolves the conflict between LED mounting requirements and electrical safety.
2Volume of moving object
If the LED dimensions are compact to reduce size, then the lamp module becomes more compact, but positioning the LEDs into corresponding holes of the barrier becomes difficult
Solution Approach 1:
The patent divides the barrier into two separate metal barriers with corresponding openings, and divides the insulator system into two insulators. This segmentation allows the LED to be positioned through the opening of the first insulator without requiring precise alignment with the second metal barrier, as the second insulator is positioned afterward to cover the leads. The segmentation of the barrier and insulator system reduces the positioning precision requirements while maintaining compact dimensions.
3Reliability
If a metal barrier is used to cover the circuit board for safety, then the risk of shock or injury is reduced, but the conductive leads may contact the metal barrier causing short circuits
Solution Approach 1:
The patent introduces a second insulator as an intermediary component positioned between the metal barrier and the LED leads. This second insulator specifically covers the conductive leads, preventing direct contact with the metal barrier and eliminating the short circuit risk while maintaining the safety function of the metal barrier in covering the circuit board.
Solution Approach 2:
The patent applies different insulating solutions to different locations: the first insulator with openings is used where LED passage is required, while the second insulator is specifically positioned to cover the conductive leads. This local differentiation of insulator placement and function allows the metal barrier to provide overall safety coverage without creating short circuit hazards at the LED lead locations.
Data Source
AI summary
A lamp module is provided, including a circuit board, at least an LED, an insulator and a metal barrier. The LED is disposed on the circuit board and has two conductive leads on opposite sides thereof. The insulator is disposed on the circuit board, having an opening and two protruding sheets. The metal barrier is disposed on the insulator, wherein the LED and the protruding sheets are extended through the metal barrier. The conductive leads are insulated from the metal barrier by the protruding sheets of the insulating member.