LED Module Packaging Cradles with Holding Tabs
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Solution Overview
Problem
Existing packaging for interconnected LED modules is disorganized, leading to tangling and difficulties in determining the length of modules, cutting, and visual inspection, with hidden modules making electrical testing challenging.
Innovation Solution
A packaging system featuring cradles with opposing side vertical surfaces and protruding tabs to hold LED modules securely, allowing interconnecting wires to be cut while modules remain in place, with a cover for protection and visibility for inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If LED modules are packaged loosely in bags or boxes, then packaging simplicity is maintained, but organization and ease of operation deteriorate due to tangling and difficulty in determining module length
Solution Approach 1:
The packaging structure is segmented into multiple individual cradles arranged in rows, each cradle holding a single LED module in a predetermined orientation. This segmentation prevents tangling and disorganization while maintaining packaging efficiency, directly resolving the contradiction between simplicity and operability.
2Ease of operation
If LED modules are wound on a dispensing roll, then ease of dispensing is improved, but measurement precision and ease of operation worsen due to difficulty in determining module length and cutting location
Solution Approach 1:
The LED modules are pre-positioned in individual cradles in their final intended arrangement before packaging. This preliminary positioning allows the user to see exactly how many modules are present and where to cut, eliminating the need to unwind and measure from a roll, thus resolving the measurement precision issue while maintaining dispensing convenience.
3Quantity of substance
If modules are hidden below other modules on a roll, then packaging density is improved, but ease of operation and reliability worsen due to difficulty in visual and electrical testing
Solution Approach 1:
Instead of stacking modules vertically where lower modules are hidden, the packaging uses multiple rows of cradles arranged horizontally. This dimensional rearrangement allows all modules to be visible from above while maintaining high packaging density, enabling easy visual inspection and testing without sacrificing quantity capacity.
4Ease of operation
If cradles are designed with opposing side vertical surfaces and protruding tabs, then ease of operation improves for secure holding, but device complexity increases
Solution Approach 1:
The cradle structure concentrates complexity only where needed: opposing side vertical surfaces and protruding tabs are provided only at the locations necessary to secure the LED modules, while other areas of the packaging remain simple. This localized application of structural features resolves the contradiction by providing secure holding without unnecessary overall complexity.
Data Source
AI summary
A package for holding a plurality of LED modules interconnected by wire. The package comprises a plurality of cradles each of which is sized to hold a respective one of the interconnected LED modules. Each of the cradles comprises first and second opposing side vertical surfaces partially defining a space for holding its respective one of the LED modules, each of the LED modules arranged in a respective one of the cradles. A plurality of holding tabs is included at least one of which is on one of the first and second opposing side vertical surfaces of each of the cradles and protruding into the module holding space. Each of the tabs is arranged to hold its respective one of the modules in its cradle, wherein the cradles are arranged adjacent to one another with the interconnecting wire running between adjacent cradles.