Tool-Free LED Lamp Assembly via Snap-Fit Fasteners
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Solution Overview
Problem
Conventional LED lamps require tools for assembly and disassembly, which is inconvenient and can damage the plastic transparent mask due to excessive force, leading to potential damage and the need for replacement.
Innovation Solution
An assembly structure for an LED lamp that uses a cover plate with slots, a LED module with an insertion hole, and fasteners with elastic arms and locking blocks, allowing tool-free assembly and disassembly, and a transparent mask with locking flanges that insert into the slots, eliminating the need for screw holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screw elements are used to assemble the transparent mask and metallic heat-dissipating cover, then the components can be firmly connected, but the operator needs to use tools and excessive force may damage the plastic mask
Solution Approach 1:
The patent replaces the screw-based mechanical fastening system with a snap-fit fastening system. The fastener includes an elastic arm with a locking block that engages with a groove on the cover plate, eliminating the need for screwdrivers and excessive tightening force. This substitution maintains connection strength while dramatically improving ease of operation.
Solution Approach 2:
The elastic arm with locking block provides self-locking functionality during assembly. When the fastener is inserted, the elastic arm automatically engages with the cover plate groove and locks into place without requiring external tools or excessive force from the operator. The design also allows for easy tool-free disassembly by pressing the release structure.
2Ease of manufacture
If screw holes are provided in the plastic transparent mask for assembly, then the components can be connected, but the mask may be damaged due to excessive force during screw tightening
Solution Approach 1:
The patent extracts the screw holes from the transparent mask design entirely. Instead of providing screw holes in the plastic mask, the fastening system is redesigned so that the fastener connects directly to the metallic cover plate through its groove structure. This extraction eliminates the vulnerability of the mask to screw-induced damage while maintaining assembly capability.
Solution Approach 2:
The fastener acts as an intermediary component that mediates the connection between the transparent mask and the metallic cover plate. Rather than directly fastening screws into the mask, the fastener with its elastic arm and locking block engages with the cover plate groove, providing a protective intermediate layer that prevents direct mechanical stress on the mask material.
3Ease of repair
If the operator uses one hand to hold the component and the other hand to tighten screws, then the assembly can be completed, but the operation becomes very inconvenient and time-consuming
Solution Approach 1:
The patent replaces the screw-tightening mechanical system with a snap-fit system that can be operated with one hand. The fastener's elastic arm automatically engages with the cover plate groove when inserted, eliminating the need for two-handed operation with screwdrivers. This substitution dramatically reduces assembly time and operational complexity.
Solution Approach 2:
The fastener is pre-designed with the elastic arm and locking block structure that automatically performs the fastening action upon insertion. The preliminary design of the self-locking mechanism means that no additional tightening action is required during assembly, reducing the assembly process to a simple insertion motion that can be completed quickly with one hand.
Data Source
AI summary
An assembly structure for a LED lamp includes a cover plate, a LED module, fasteners and a mask. An inner surface of the cover plate is provided with a fixing portion. Both sides of the cover plate are formed with a slot respectively. The LED module has a substrate and a plurality of LED mounted on the substrate. The substrate is provided with an insertion hole. One end of the fastener is detachably connected into the insertion hole of the substrate and the other end thereof is fixed to the fixing portion. The mask is made of transparent materials and has an accommodating space for allowing the LED module to be disposed therein. Both sides of the mask defining the accommodating space are formed with a locking flange for inserting into the slot of the cover plate. With the above arrangement, the operator can assemble or detach the LED lamp quickly.