LED Module Mounting with Integrated Head Elements

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Solution Overview

Problem

Existing LED module mounting systems lack efficient electrical and mechanical connections, and do not facilitate easy replacement or thermal dissipation, limiting their performance and adaptability in lighting applications.

Innovation Solution

A lighting unit with an LED module attached to the outside of a housing, utilizing a power rail and busbar with conductive head elements for secure electrical connections and thermal conductivity, allowing for easy module exchange and thermal management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional mounting systems are used for LED modules, then the structure is simple, but the electrical connection reliability is poor and contact resistance is high

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmounting system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines mechanical mounting and electrical connection functions into a single integrated head element. The head element simultaneously secures the LED module mechanically and establishes electrical contact through integrated contact elements that engage with busbars, eliminating the need for separate mechanical fasteners and electrical connectors.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The head element serves multiple functions: it acts as a mechanical fastener to secure the LED module, provides electrical contact through integrated contact elements, and facilitates thermal management. This multi-functional design improves connection reliability while managing system complexity through consolidation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of repair

If traditional mounting systems are used for LED modules, then the manufacturing process is simple, but the module replacement is difficult

Engineering Contradiction:

Improvemodule replacement easeVSAvoidmanufacturing complexity

Core Design Contradiction:

Ease of repairVSEase of manufacture

Solution Approach 1:

The mounting system is segmented into modular components: the head element with integrated contact elements, the busbar with contact regions, and the LED module with mounting holes. This segmentation allows the LED module to be easily removed and replaced by simply disengaging the head elements, while the head elements themselves can be pre-assembled on the busbar during manufacturing.

Inventive Principle:

Principle #1Segmentation

3Reliability

If conventional connection methods are used, then the contact resistance is high, but the manufacturing cost is low

Engineering Contradiction:

Improvecontact resistanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces traditional mechanical fastening systems with an integrated head element design that combines mechanical retention and electrical contact. The head elements engage with the LED module through threaded holes or recesses, providing both mechanical security and low-resistance electrical contact through direct metal-to-metal contact with the busbar.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Adaptability or versatility

If LED modules are permanently mounted, then the structural stability is high, but the adaptability to technology advancements is poor

Engineering Contradiction:

Improvetechnology adaptabilityVSAvoidstructural stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The mounting system transitions from a permanent fixed connection to a dynamic, reversible connection. The head elements can be easily removed and reattached, allowing LED modules to be replaced with updated versions while maintaining structural stability during operation. The threaded engagement or recess-fit design provides stable mounting during use but allows easy removal when needed.

Inventive Principle:

Principle #15Dynamics

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 reliable electrical and mechanical connections with low contact resistance, efficient heat dissipation, and modular design enabling easy replacement of LED modules, ensuring adaptability with advancements in LED technology.

Implementation Method 1

A contact element for each pole of the LED module is mechanically and electrically connected to the busbar

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

The underside of the head projecting over its shaft rests against the front side of the LED module facing away from the housing

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP2143989B1Lighting unit, LED module and method

Publication Date: 2011.05.18 WURTH ELEKTRONIK ROT AM SEE

Figure 1~8
Figure 9~13
Figure 14

AI summary

The unit has an LED module (4) arranged at an outer side of a housing. A printed circuit board (1) with a printed circuit board carrier is provided for supplying current to the LED module. A head element (12) e.g. casing element, and another head element are connected with contact elements (15) by an opening (11) of the housing, where the head elements manufacture connections for the LED module at a front side of the housing. The head element exhibits a head with a lower side that lies at a front side of the carrier of the LED module.