LED Module Passageways for Seamless Electrical Connections
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Solution Overview
Problem
Existing linear LED lighting devices face challenges in achieving uniform illumination due to the presence of connectors and wiring, which can create dark areas and require additional installation complexities, especially when multiple modules are connected or installed in profiled bars or recessed positions.
Innovation Solution
The solution involves creating passageways through the encapsulation layer of the lighting device for electrically-conductive formations to minimize external dimensions and eliminate protrusions, allowing for seamless connection and installation without visible dark areas, using methods like piercing or punching to expose conductive paths and applying sealing materials for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connectors and wiring systems are used to establish electrical connections, then electrical connectivity is achieved, but the device dimensions increase and protrusions are created
Solution Approach 1:
The patent merges the electrical connection function with the module housing by integrating connectors directly into the housing structure. The housing serves dual purposes: structural enclosure and electrical connection interface, eliminating the need for separate protruding connectors and wiring systems.
Solution Approach 2:
The module housing is designed to perform multiple functions simultaneously: mechanical protection of internal components, structural support, and electrical connection interface. This multi-functionality eliminates the need for dedicated separate components for each function, reducing overall device dimensions.
2Ease of manufacture
If connectors are located at one end of the module, then electrical connection is simplified, but dark non-lighted areas are created between adjacent modules
Solution Approach 1:
The patent implements different connection configurations at different ends of the module. One end features a female connector while the other end features a male connector, allowing flexible arrangement where connectors can be positioned at module ends without creating visible dark areas in the final installation.
Solution Approach 2:
The patent transitions from a single-plane connection approach to a three-dimensional arrangement where male and female connectors are positioned at opposite ends of the module, allowing connections to be made in different spatial dimensions and avoiding the creation of dark areas between adjacent modules.
3Reliability
If dedicated grooves or seats are created for connectors in profiled bars or recessed positions, then proper installation is achieved, but installation time and costs increase
Solution Approach 1:
The module housing is designed with self-aligning features that allow connectors to automatically find their correct position during installation. The integrated connector design with positioning elements enables the module to self-align within the profiled bar or recessed position without requiring pre-formed dedicated grooves or seats.
Solution Approach 2:
The connectors are pre-integrated into the module housing during manufacturing with built-in positioning and alignment features. This preliminary integration of connection and positioning functions eliminates the need for on-site creation of dedicated grooves or seats, significantly reducing installation time and complexity.
4Length of stationary object
If wiring systems are positioned to not protrude beyond module dimensions, then device compactness is improved, but cables create shaded areas at the light-radiation emitting surface
Solution Approach 1:
The patent nests the wiring system within the module housing structure. Cables and wires are routed through channels and passages integrated into the housing, allowing them to be contained within the module's external dimensions without creating protrusions or shaded areas on the light-emitting surface.
Data Source
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AI summary
A method for installing a lighting device (10), such as, for example, an LED module comprising an elongated body having a first, light-emitting surface (10a) and at least one second rear (10b) or side surface, with an encapsulation layer at the second surface (10b), and a distribution of electrically-powered light radiation sources (12) arranged in the elongated body along the length thereof to project light radiation towards the light-emitting surface (10a). Electrically-conductive formations (14) are provided for transferring electrical signals with respect to the light radiation sources (12), which pass through one or more passageways (140) in the encapsulation layer (100) at the second surface (10b).