LED Socket Assembly Snap-Fit Mounting Clip
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Solution Overview
Problem
Existing LED lighting systems face challenges with time-consuming and costly assembly processes due to mechanical hardware and adhesive mounting, and unreliable solder connections, which complicate the replacement of LEDs and PCBs.
Innovation Solution
A socket assembly with a socket housing and mounting clip that uses a snap-fit connection to securely attach to the lighting fixture base, eliminating the need for mechanical hardware and adhesives, and featuring a receptacle for the LED and power connectors for easy electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical hardware and adhesives are used to mount the PCB or LED to the lighting fixture base, then the mounting is secure and reliable, but the assembly process becomes time-consuming and costly
Solution Approach 1:
The invention divides the mounting system into separate functional components: a socket housing that holds the LED, a mounting clip that attaches to the base, and a lens assembly. This segmentation allows each component to be independently manufactured and assembled, enabling quick snap-fit installation without time-consuming mechanical fastening or adhesive application while maintaining secure mounting through the interlocking clip design
Solution Approach 2:
The invention replaces traditional mechanical fastening systems (screws, rivets) and adhesive bonding with a snap-fit plastic clip mechanism. The mounting clip features resilient arms that deflect during installation and snap into place on the base, providing secure mechanical attachment without requiring tools, fasteners, or adhesives, thereby dramatically reducing assembly time and cost
2Reliability
If soldering is used to connect electrical power wires to the PCB, then the electrical connection is reliable, but the process becomes time-consuming and costly
Solution Approach 1:
The invention replaces the soldering process with a mechanical wire insertion system. Pre-attached wire assemblies with forked terminals are designed to snap into corresponding receptacles on the socket housing, providing secure electrical connections through mechanical engagement rather than thermal bonding. This eliminates the need for soldering equipment, skill, and time while maintaining reliable electrical contact through the resilient forked terminal design
Solution Approach 2:
The electrical connections are pre-assembled during manufacturing by attaching wire assemblies with forked terminals to the socket housing before final installation. This preliminary action ensures that electrical connections are already prepared and positioned correctly, eliminating the need for on-site wire stripping, bending, and soldering operations, thereby reducing assembly time and labor costs
3Reliability
If LEDs and PCBs are mounted using traditional methods, then the connection is secure, but replacement becomes tedious and requires skilled personnel
Solution Approach 1:
The invention segments the LED lighting assembly into modular components: a socket housing containing the LED and electrical connections, a mounting clip for base attachment, and a lens assembly. This modular design allows the LED module to be independently removed and replaced by simply disengaging the mounting clip and wire connections, eliminating the need to work with soldered PCBs and making replacement a simple, tool-free operation that does not require skilled technicians
Solution Approach 2:
The mounting clip incorporates resilient, deflectable arms that allow the socket housing to be easily inserted and removed from the base. During installation, the arms deflect to accommodate the housing, then snap back to secure it. During replacement, the arms can be manually deflected to release the housing, enabling quick, reversible mounting that maintains security during operation but allows easy replacement when needed
Data Source
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AI summary
A socket assembly (14) is provided for mounting on a base of a lighting fixture. The socket assembly (14) includes a socket housing (36) having a base side (54), a clip side (50), and a side wall (46) extending from the base side (54) to the clip side (50). The base side (54) of the socket housing (36) is configured to be mounted on the base of the lighting fixture. The socket housing (36) includes a receptacle (62) extending therein. A light emitting diode (LED) (18) is held within the receptacle (62) of the socket housing (36). The socket assembly (14) further includes a mounting clip (38) having a strap (72) and an arm (74) that extends from the strap (72). The strap (72) extends over and is engaged with the clip side (50) of the socket housing (36). The arm (74) extends outwardly from the strap (72) along the side wall (46) of the socket housing (36) and is configured to engage the base of the lighting fixture to hold the socket housing (36) on the base.