LED Lamp Housing Deformation for Screw-Free Assembly
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Solution Overview
Problem
Existing LED lamp assembly methods, such as screw connections, can lead to breakage of plastic lamp housings, hazardous electrical conductors, high costs, and complexity due to drilling and adhesive application, which compromise insulation and increase the risk of electric shock.
Innovation Solution
A screw-free connection method where a carrier circuit board is inserted into a lamp housing with projections that are deformed to create a form-fitting and force-fitting interface, eliminating the need for drilling and screwing, and optionally using an insulating layer and a die to ensure secure positioning and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screw connections are used to attach the carrier circuit board to the lamp housing, then a secure mechanical connection is achieved, but the plastic lamp housing may break due to excessive tightening and electrical conductors may be exposed creating safety hazards
Solution Approach 1:
The patent replaces the screw connection system with a deformation-based mechanical interlocking system. Projections on the carrier circuit board are deformed during insertion into the lamp housing, creating a secure connection without screws. This eliminates the harmful effects of screw tightening (housing breakage) and exposed conductors (electrical shock risk) while maintaining connection strength.
Solution Approach 2:
The patent introduces an intermediate deformation mechanism where projections are elastically deformed during insertion and then recover to lock the carrier circuit board in place. This intermediate process acts as a mediator between the carrier circuit board and lamp housing, providing secure attachment without direct mechanical fastening that could cause damage or exposure.
2Strength
If drilling holes are created for screw connections, then secure attachment is achieved, but insulation of electrical conductors may be damaged by metal chips or screw ends
Solution Approach 1:
The patent replaces the drilling and screwing process with a deformation-based insertion process. Projections are deformed during insertion into the lamp housing without requiring drilled holes, thereby eliminating the generation of metal chips and the risk of exposed screw ends that could damage electrical conductor insulation.
Solution Approach 2:
The patent performs preliminary deformation of the projections before insertion, preparing them to flex during the insertion process. This preliminary action ensures that the projections can accommodate the insertion process without creating harmful byproducts like metal chips, and without requiring post-insertion fastening that could expose conductors.
3Ease of operation
If adhesive bonding is used to attach the carrier circuit board, then a screw-free connection is achieved, but the process becomes complex and time-consuming due to adhesive application requirements
Solution Approach 1:
The patent replaces adhesive bonding with a purely mechanical deformation-based system. The projections are deformed during insertion and recover to create a secure mechanical interlock, eliminating the need for adhesive application entirely. This maintains the screw-free advantage while removing the complexity and time constraints associated with adhesive curing.
Solution Approach 2:
The deformation process is self-service in nature - the projections themselves provide both the insertion mechanism and the locking mechanism through their elastic deformation and recovery. No external adhesive material is required, and no additional bonding steps are needed, simplifying the overall process while maintaining ease of operation.
4Ease of manufacture
If projections are deformed to create a force-fitting connection, then assembly is simplified and costs are reduced, but the deformation process must be precisely controlled to avoid damage
Solution Approach 1:
The patent utilizes parameter changes in the material properties of the projections, specifically their elastic characteristics. By selecting materials with appropriate elastic moduli and designing projection geometries with specific dimensions, the deformation process achieves the desired balance between assembly simplicity and manufacturing precision. The projections deform controllably during insertion and recover to provide secure locking without requiring excessive precision control.
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 simplifies and cost-reduces the assembly process, enhances safety by avoiding electrical conductor exposure, and provides a flexible and secure connection between the lamp housing and carrier circuit board, ensuring effective heat transfer and insulation.
Implementation Method 1
the projection is at least partially deformed in such a way that the lamp housing is pressed with the carrier circuit board
Implementation Method 2
the projection is at least partially deformed in such a way that the lamp housing is pressed with the carrier circuit board
Implementation Method 3
the projection is at least partially deformed in such a way that the lamp housing is pressed with the carrier circuit board
Data Source
AI summary
A method for producing an LED lamp includes a lamp housing wherein at least one carrier circuit board equipped with LEDs is inserted into the lamp housing in such a way that at least a subregion of the lamp housing protrudes beyond the carrier circuit board with a projection, and the projection is at least partially deformed after insertion in such a way that the lamp housing is pressed with the carrier circuit board.