LED Lighting Device with Potting and Adaptor Board

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Solution Overview

Problem

Current lighting devices intended for wet and/or dusty environments, such as bathrooms or outdoor illumination, lack reliable protection against environmental influences and have complex, costly assembly processes that are not automated.

Innovation Solution

A lighting device comprising an LED module connected to a retainer via an adaptor board, with the driver electrically connected to the retainer through the adaptor board, and partially cast with potting material for enhanced protection against water and dust, allowing for automated and cost-effective assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a complex assembling process is used to achieve reliable sealing against water and dust, then protection against environmental influences is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improveprotection against environmental influencesVSAvoidassembling process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The device is divided into separate functional modules (LED module, driver module, reflector) that can be independently manufactured and then assembled. The adaptor board segments the electrical connection function, separating it from both the driver and retainer, allowing each component to be optimized independently while maintaining reliable connections through standardized interfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The adaptor board serves as an intermediary component between the driver and retainer, providing both electrical connection and mechanical positioning. This intermediary element simplifies the overall assembly process by consolidating multiple functions (electrical connection, mechanical support, alignment) into a single component that can be easily integrated.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If traditional sealing methods are used to protect against water and dust, then protection is improved, but the assembling process becomes more complex and costly

Engineering Contradiction:

Improvesealing protectionVSAvoidassembling process ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The sealing function is merged with the potting material that encapsulates the driver circuit board. Instead of using separate sealing components (gaskets, seals, or coatings), the potting material simultaneously provides electrical insulation, mechanical support, and environmental sealing in a single manufacturing step that is compatible with automated assembly.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The potting material transforms the driver assembly from an exposed electrical component into a sealed, protected unit. By changing the physical state and properties of the driver mounting (from open circuit board to encapsulated structure), the sealing protection is achieved through material parameter changes rather than additional mechanical sealing components.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If automated assembling is implemented to reduce cost, then manufacturing cost is reduced, but achieving reliable sealing becomes more difficult

Engineering Contradiction:

Improvemanufacturing costVSAvoidsealing protection

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The adaptor board is pre-configured with connection terminals and mounting features before assembly. The driver module and LED module are pre-assembled as complete functional units with their respective electrical connections and mechanical interfaces already established, enabling straightforward automated integration without complex real-time adjustments.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Traditional mechanical sealing systems (screws, gaskets, snap-fits) are replaced with a potting material system that provides sealing through material properties rather than mechanical fastening. This substitution enables automated application of the sealing medium and eliminates the need for complex mechanical assembly steps while maintaining reliable environmental protection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The solution provides a compact, robust lighting device with improved protection against environmental influences, meeting IP 65 standards for dust and water resistance, and simplifies the assembly process by using an adaptor board for electrical connections and potting material for sealing.

Implementation Method 1

the driver is at least partially cast

Methodology Applied

Scientific EffectPotting material casting:

Data Source

PatentUS10473319B2Lighting device, LED module for a lighting device, and method for assembling a lighting device

Publication Date: 2019.11.12 LEDVANCE GMBH

AI summary

A lighting device is provided, comprising at least one LED module, which is connected to a retainer, and a driver that is electrically connected to the LED module, wherein the driver is at least partially cast by a potting material wherein the driver is connected to the retainer via an adaptor board that is positioned in between the driver and the retainer.