LED Lighting Module Integrated Driver Housing Design
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Solution Overview
Problem
The challenge lies in implementing concepts involving identical parts for LED modules, where the geometrical form factors of LED modules with multiple printed circuit boards connected by cable connections make it difficult to achieve a compact design and efficient assembly, while also ensuring protection classes like type I, II, or III.
Innovation Solution
A lighting module design featuring a housing with an open rear side, a light source substrate, a driver circuit board, and electrical connection elements, including a closure element for sealing, which allows for reduced thermal processing, compact design, and modular construction, enabling the accommodation of driver circuit board components and ensuring protection classes through tight sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If LED modules use multiple printed circuit boards connected by cable connections, then the functional requirements can be met, but the design becomes complex and difficult to standardize
Solution Approach 1:
The patent merges the driver circuit board and light source substrate into a single integrated housing structure. The driver circuit board is positioned within the housing such that its rear side is open, allowing direct electrical connection to the light source substrate without requiring separate cable connections. This integration eliminates the complexity of multiple separate circuit boards connected by cables while maintaining functional requirements.
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it provides mechanical support for the driver circuit board and light source substrate, ensures electrical connection through the open rear side, and enables standardization through its modular design. The closure element with feedthroughs provides both sealing and electrical connection pathways, further reducing overall complexity.
2Ease of manufacture
If cable connections are used to connect multiple printed circuit boards, then electrical connection is achieved, but assembly thermal processes increase
Solution Approach 1:
The patent extracts the cable connection element from the assembly process entirely. Instead of using cables to connect circuit boards, the design employs direct electrical connection through the open rear side of the housing, eliminating the need for cable assembly and associated thermal processes.
Solution Approach 2:
The driver circuit board is pre-positioned within the housing with its rear side open, and the light source substrate is pre-mounted on the front side. This preliminary arrangement allows for direct electrical connection without requiring subsequent cable connection steps, simplifying the overall assembly process.
3Reliability
If the housing is tightly sealed to fulfill protection classes, then environmental protection is improved, but the design becomes less modular
Solution Approach 1:
The housing provides tight sealing and environmental protection specifically for the driver circuit board and light source substrate areas that require protection. The closure element with feedthroughs creates sealed compartments while maintaining modular accessibility. This localized sealing approach maintains protection classes without completely restricting modular construction capabilities.
Solution Approach 2:
The housing is designed as a modular unit that can be assembled and disassembled, with the closure element providing sealed compartments. This segmentation allows the housing to maintain protection classes while remaining suitable for modular construction and assembly processes.
Data Source
AI summary
A lighting module may include a housing having an open rear side, a light source substrate with at least one light source arranged thereon, a driver circuit board accommodated in the housing, at least one electrical connection element for electrically connecting the driver circuit board to the light source substrate, and a closure element for closing the open rear side, wherein the closure element is designed for feeding through at least one electrical connection.