Modular LED Assembly with Fixating Optical Boards
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Solution Overview
Problem
LED-based luminaires face challenges with high manufacturing costs, complex maintenance, and inefficient component management due to the need for multiple types of printed circuit boards (PCBs) and optical elements, which increases production costs and logistical complexities.
Innovation Solution
The solution involves a modular LED-based assembly where optical boards are used to fix multiple circuit boards together, allowing for flexible assembly without a chassis, enabling easier manufacturing, maintenance, and recycling, and reducing the need for specialized equipment and storage space by standardizing circuit and optical boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple types of PCBs and optical elements are used to comply with various designs and specifications, then the adaptability of LED-based systems is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies universality by designing a standardized PCB structure that can accommodate multiple LED configurations and optical element arrangements. The PCB includes standardized mounting areas, electrical connection patterns, and mechanical interfaces that work across different luminaire designs, reducing the need for multiple specialized PCB types while maintaining adaptability to various specifications
Solution Approach 2:
The patent segments the LED assembly into modular components including the PCB, optical elements, and mounting structures that can be independently configured. This segmentation allows different combinations of standard components to create varied luminaire designs without requiring custom PCBs for each application
2Adaptability or versatility
If multiple types of PCBs and optical elements are used to comply with various designs and specifications, then the adaptability of LED-based systems is improved, but the manufacturing cost increases
Solution Approach 1:
The standardized PCB design serves multiple luminaire types and applications, allowing a single PCB type to be manufactured in large volumes for different products. This universality reduces tooling costs, simplifies supply chain management, and lowers per-unit manufacturing costs while maintaining the ability to adapt to various design requirements through configuration rather than custom fabrication
Solution Approach 2:
The patent utilizes parameter changes by modifying the configuration, arrangement, and specification of standardized components (such as LED placement patterns, optical element types, and electrical connection layouts) on a universal PCB platform. This allows cost-effective adaptation to different requirements without changing the fundamental PCB design, enabling economies of scale in manufacturing
3Ease of operation
If a large-sized PCB is used to connect all LEDs, then the handling and releding is simplified, but the foundry costs and manufacturing complexity increase
Solution Approach 1:
The patent segments the LED array into multiple smaller PCB modules rather than using one large PCB. Each module can be independently manufactured, handled, and tested, reducing foundry costs and manufacturing complexity. The modular design maintains ease of operation by allowing standardized handling procedures to be applied to smaller, more manageable units that can be easily assembled and replaced
4Adaptability or versatility
If there is a high number of types of PCBs and optics in stock, then the various designs and specifications can be complied with, but the stock management becomes inefficient and delivery lead time increases
Solution Approach 1:
The standardized PCB design reduces the variety of components that need to be stocked. A single universal PCB type can satisfy multiple design and specification requirements through different configurations of LEDs and optical elements, thereby reducing inventory complexity and improving stock management efficiency without compromising the ability to comply with various luminaire specifications
Data Source
AI summary
The invention refers to a LED-based assembly (100) comprising: —an electrical device comprising circuit boards (110-1,110-2) arranged to drive and/or supply arrays of LEDs (111-1,111-2) electrically and mechanically connected thereto; —an optical device provided onto the electrical device and comprising optical boards (120) partly mounted onto the circuit boards (110-1,110-2).