Tool-Free Fastening Element for LED Substrates
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Solution Overview
Problem
Existing fastening methods for lighting modules to supports are complex, require tools, and do not efficiently manage thermal expansion, leading to potential disconnection and increased costs.
Innovation Solution
A fastening element that sits on the light source substrate, featuring a pivotable lever and contact surfaces for secure attachment to the support without dedicated fastening means like screws, allowing for easy assembly and improved thermal contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional fastening methods (screws, clips) are used to attach lighting modules to supports, then secure attachment is achieved, but assembly complexity increases and tool-free assembly is lost
Solution Approach 1:
The patent combines the fastening function with the support structure itself by integrating fastening elements (protrusions and recesses) directly into the support. This eliminates the need for separate fastening components like screws or clips, enabling tool-free assembly while maintaining secure attachment. The support structure serves dual purposes: providing mechanical support and enabling fastening through integrated elements.
Solution Approach 2:
The lighting module and support are designed with complementary fastening elements (protrusions on one component and corresponding recesses on the other) that enable self-alignment and self-fastening during assembly. The components fasten themselves together through simple insertion and engagement of these integrated elements, eliminating the need for external fastening tools or additional fastening components.
2Stability of the object's composition
If rigid fastening structures are used to secure lighting modules, then stable attachment is achieved, but thermal expansion mismatches cause connection failures
Solution Approach 1:
The patent employs elastic fastening elements (such as elastic protrusions or flexible support structures) that can dynamically adapt to thermal expansion and contraction. These elastic elements maintain continuous contact and secure attachment while accommodating dimensional changes caused by thermal effects, preventing connection failures that would occur with rigid fastening structures.
Solution Approach 2:
The fastening structure incorporates elements with varying material properties or geometric configurations that allow controlled deformation under thermal load. By designing fastening elements that can change their physical parameters (such as elasticity, flexibility, or engagement depth) in response to temperature changes, the system maintains reliable connection despite thermal expansion mismatches between different components.
3Strength
If multiple separate fastening components are used, then secure attachment is achieved, but manufacturing costs and handling complexity increase
Solution Approach 1:
The patent integrates fastening functions into the existing support structure and lighting module components, eliminating the need for separate fastening parts. By combining multiple functions (support, fastening, and thermal management) into unified components with integrated fastening elements, the design reduces part count, simplifies manufacturing, and lowers costs while maintaining secure attachment strength.
Solution Approach 2:
The support structure and lighting module components are designed to serve multiple functions simultaneously: providing mechanical support, enabling fastening through integrated protrusions and recesses, and facilitating thermal management. This multi-functionality eliminates the need for dedicated separate fastening components, reducing manufacturing complexity and cost while maintaining attachment strength.
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
Enables easy, tool-free assembly of lighting modules with enhanced thermal efficiency and secure attachment, reducing costs and handling complexity while compensating for thermal expansion.
Implementation Method 1
The metal strip 118 is under tension so that it presses the ring cover onto the printed circuit board 102 under all thermal load conditions
Implementation Method 2
a layer of thermal interface material 3, such as a thermal paste, a thermally conductive foil or a thermally conductive adhesive, attached to the heat sink 2
Implementation Method 3
The coefficient of thermal expansion of the material of the surrounding portion of the first member is greater than the coefficient of thermal expansion of the material of the surrounding portion of the second member
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The fastening element (4) serves to fasten a light source substrate (102) to a support (2), in particular without tools and in a releasable manner, wherein the fastening element is designed to sit on the light source substrate, and has at least one fastening means (6) in order to be fastened to the support. The luminous module (1) has at least one light source substrate (102) with a light source (106) which is arranged on a front face (105) of the light source substrate, and has the fastening element (4), wherein the fastening element sits on the front face (105) of the light source substrate (102). The luminous apparatus has a luminous module, wherein the light source substrate also rests on a support by way of its rear face and the fastening element both sits on the front face of the light source substrate and is fastened to the support. The luminous apparatus can also have a cover for covering at least part of a light source substrate, wherein the light source substrate rests on a support, and wherein the cover sits on the light source substrate and is clamped to the support by means of at least one independent fastening means.