Two-Piece LED Module Connection Ring for Flexible PCB Assembly
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Solution Overview
Problem
The luminaire industry faces the challenge of needing to stock a large number of pre-assembled LED light module and heat sink variants due to varying circuit board sizes and LED outputs from different manufacturers, leading to high inventory requirements.
Innovation Solution
A two-piece connection element comprising a first ring that surrounds the circuit board horizontally and a second ring that overlaps it vertically, allowing for partial assembly and flexible adaptation to different circuit boards, with one ring anchored to a counter bearing for mechanical fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple variants of pre-assembled LED light modules are kept in stock to meet different customer requirements, then the ability to fulfill diverse luminaire intensity and color temperature needs is improved, but the inventory complexity and storage requirements increase significantly
Solution Approach 1:
The connection element is divided into a first ring and a second ring that can be separated from each other. The first ring remains fixed on the heat sink, while the second ring can be removed and replaced with different variants to accommodate different LED circuit board specifications. This segmentation allows the system to adapt to diverse luminaire requirements without maintaining complete pre-assembled inventory for each variant.
Solution Approach 2:
The first ring is designed as a universal component that can accommodate multiple different LED circuit board variants through the interchangeable second ring. The standardized interface between rings allows a single first ring to serve multiple functions across different luminaire configurations, reducing the need for multiple specialized pre-assembled units.
2Quantity of substance
If LED circuit boards are selected and assembled at the time of final luminaire production, then inventory storage requirements are reduced, but the assembly process becomes more complex
Solution Approach 1:
By separating the connection element into two rings with a standardized interface, the patent simplifies the final assembly process. The second ring can be easily attached to the first ring in a straightforward connection operation, making the delayed assembly of specific LED circuit boards simple and efficient rather than complex.
3Device complexity
If a single connection element design is used for all LED circuit board variants, then manufacturing and inventory management are simplified, but the ability to accommodate different circuit board sizes and specifications is reduced
Solution Approach 1:
The connection element is segmented into a standardized first ring and interchangeable second rings. The first ring maintains a simple, uniform design that simplifies manufacturing, while the second ring variants accommodate different LED circuit board specifications. This segmentation allows the system to maintain design simplicity while achieving versatility.
Solution Approach 2:
The first ring is designed as a universal base that can work with multiple second ring variants, each adapted to different LED circuit board types. This universal design approach allows a single first ring design to serve multiple functions across various circuit board specifications, maintaining manufacturing simplicity while achieving broad compatibility.
Data Source
AI summary
A connection element for the electrical connection of an LED light module is described. The LED light module has a circuit board with contact pads for supplying electricity to the LED. A substantially ring-shaped frame is provided to overlap the circuit board and to hold it mechanically on a mounting surface of a counter bearing. A contact arrangement is mounted in the frame and serves to supply electricity to the LED. The frame is divided into a first ring and a second ring. The first ring is provided to surround the circuit board and to hold it in the parallel direction with respect to the mounting surface of the counter bearing, and the second ring at least partially overlaps the circuit board and is provided to hold the circuit board in the vertical direction with respect to the surface of the counter bearing.