LED Board Retention via Case Restriction and Thermal Bonding

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Solution Overview

Problem

Conventional LED lamps require securing components like screws, increasing complexity, cost, and necessitating larger boards for insulation, which complicates the configuration and raises productivity issues.

Innovation Solution

An LED light source design that sandwiches a board between a case and a support, using restricting portions to secure the board without screws, and includes a heat-dissipating bonding component for reliable attachment and heat management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a securing component such as a screw is used to secure the board to the support, then the board can be firmly attached, but the configuration becomes complex and productivity deteriorates

Engineering Contradiction:

Improveboard attachment reliabilityVSAvoidconfiguration complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent removes the securing component (screw) from the system and replaces it with a board retention structure integrated into the case. The case includes a retention portion that directly holds the board against the support, eliminating the need for separate fastening elements and simplifying the overall configuration.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent merges the board retention function into the case structure itself. The retention portion is formed as an integral part of the case, combining the case's structural support function with the board retention function, thereby eliminating the need for separate securing components.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If a securing component such as a screw is used, then the board can be secured, but the configuration becomes complex and cost increases

Engineering Contradiction:

Improveboard attachment reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent eliminates the securing component (screw) from the bill of materials and replaces it with a board retention structure that is molded as part of the case. This reduces the number of parts, simplifies manufacturing processes, and lowers overall assembly costs while maintaining reliable board attachment.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The retention function is merged into the case structure through a retention portion that is formed integrally with the case. This eliminates the need for separate securing components, reducing part count and manufacturing complexity while maintaining reliable board attachment.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If a conductive material is used for the securing component, then the board can be secured, but a large-sized board is required to ensure adequate insulation distance

Engineering Contradiction:

Improveboard attachment reliabilityVSAvoidboard size

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent removes the conductive securing component (screw) from the system and replaces it with an insulating board retention structure integrated into the case. This eliminates the need for large insulation distances and allows for compact board designs while maintaining secure attachment.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The case structure acts as an intermediary between the support and the board, providing both mechanical retention and electrical insulation. The retention portion in the case provides the necessary insulation distance without requiring the board itself to be larger, as the case structure mediates between the support and board.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If restricting portions are added to the case to secure the board, then the board can be restricted from moving, but the case structure becomes more complex

Engineering Contradiction:

Improveboard position stabilityVSAvoidcase structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

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 design simplifies the configuration by eliminating the need for screws, reduces costs, and maintains adequate insulation without increasing the board size, enhancing productivity and heat dissipation.

Implementation Method 1

a bonding component disposed between the board and the support and having heat-dissipating properties

Methodology Applied

Scientific EffectHeat dissipation: Conduction (thermal)

Data Source

PatentUS9303851B2Illumination light source and lighting apparatus

Publication Date: 2016.04.05 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

An LED unit which serves as an illumination light source includes: a mounting board on which a light-emitting element, which emits light frontward, is provided; a support disposed behind the mounting board; and a case disposed so that the mounting board is sandwiched in a longitudinal direction by the case and the support. The case includes a restricting portion which restricts sideward movement of the mounting board.