Rail-Mounted LED Lighting Module with Integrated Spring Connectors
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Solution Overview
Problem
Existing lighting modules mounted on rails face challenges in providing a simple, stable, and customizable electrical, mechanical, and thermal connection, requiring additional operations and specialized devices for handling and reconfiguration to accommodate varying power levels.
Innovation Solution
A lighting module with a support element featuring integrated spring-action electrical connectors and a resilient system for retaining the circuit board, allowing for snap-engagement with a rail and optional connection to an auxiliary heat sink, enabling compact, stable mounting with integrated optical and electronic functions without additional fixing devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If dedicated lighting modules are produced to meet specific power dissipation requirements, then power dissipation capability is improved, but compatibility between modules deteriorates
Solution Approach 1:
The support element is designed with multiple functions integrated into a single component: it provides mechanical support for the circuit board, electrical connection through integrated spring-action connectors, thermal management via heat dissipation structures, and snap-engagement with the rail. This multi-functional design allows a single module type to serve multiple power requirements without sacrificing compatibility.
2Adaptability or versatility
If additional fixing devices and operations are used to accommodate varying power levels, then power configuration flexibility is improved, but device complexity and ease of operation deteriorate
Solution Approach 1:
The patent combines electrical connectors, mechanical retention, and thermal management functions into the support element itself. The spring-action connectors are integrated directly into the support structure, eliminating the need for separate wiring harnesses or connection devices. This merging of functions reduces overall device complexity while maintaining configuration flexibility.
Solution Approach 2:
The spring-action connectors provide dynamic electrical connection that can accommodate variations in power requirements. The resilient nature of the spring connectors allows for easy engagement and disengagement, enabling rapid reconfiguration of power levels without complex fixing operations.
3Stability of the object's composition
If a stable mounting structure is created with integrated functions, then mounting stability is improved, but manufacturing complexity may worsen
Solution Approach 1:
The support element is designed as a modular component that can be manufactured separately and then assembled with the circuit board and optical devices. This segmentation allows each component to be optimized for its specific function while maintaining overall manufacturing simplicity. The support element itself can be produced using standard manufacturing processes for resilient structural components.
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 solution provides a compact, stable, and easy-to-handle mounting structure that simplifies installation and replacement, allowing for flexible power configurations and efficient heat dissipation, eliminating the need for extra connection devices and facilitating modular reconfiguration.
Implementation Method 1
integrated spring-action, electrical connectors
Implementation Method 2
resilient system for retaining the circuit board
Implementation Method 3
a resilient system for retaining the circuit board
Implementation Method 4
connecting the module to an auxiliary heat sink only when the installed power is such as to exceed the intrinsic dissipation capacity of the module
Data Source
Figure 1
Figure 2a~2c
Figure 3~4
AI summary
A lighting module (10), for example of the LED type, for mounting on a rail (R) comprises a circuit board (12) for carrying one or more light radiation sources (L), and a support structure (14) with a first side (14a) facing the rail (R) and carrying the aforementioned circuit board (12) and a second side (14b) situated on the opposite side to the rail (R) and carrying one or more lenses (16) for the light radiation sources (L). The support structure (14) carries one or more flexible electrical contacts (18) having a first end (18a) protruding from the first side (14a) of the support structure (14) for making contact with an electrical line (T) provided on the rail (R) and a second end (18b) which extends towards the circuit board (12) so as to provide electrical contact for the light radiation source or sources (L).