Releasable LED Socket for Tool-Free Replacement

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Solution Overview

Problem

Existing LED mounting arrangements require heat and soldering for replacement, making it difficult and costly to replace individual LEDs in fixtures, especially in multi-LED setups, and often result in a bulky form factor.

Innovation Solution

The development of releasable LED sockets that allow for easy insertion and removal of LEDs without heat or solder, using mechanisms like spring contacts, clamp locks, and bottom contacting arrangements, enabling simple replacement with normal hand pressure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If LEDs are mounted using reflow surface mount techniques with solder, then the mounting is secure and reliable, but the replacement process becomes complex requiring heat and soldering equipment

Engineering Contradiction:

Improvemounting reliabilityVSAvoidLED replacement ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The invention divides the LED lighting system into two separable components: a reusable socket mounted on the circuit board and a replaceable LED assembly. This segmentation allows the socket to remain permanently secured while only the LED portion needs replacement, eliminating the need to re-solder the entire assembly and enabling simple tool-free replacement of LED modules.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The socket acts as an intermediary component between the circuit board and the LED assembly. It provides a mechanical and electrical interface that allows the LED module to be easily attached and detached without direct soldering to the board, thus maintaining reliable electrical connection while enabling simple replacement operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If traditional soldered mounting is used, then the connection is secure, but the replacement cost and time increase

Engineering Contradiction:

Improveconnection strengthVSAvoidreplacement time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The socket is pre-mounted and secured to the circuit board during manufacturing with permanent mechanical attachment and soldering. This preliminary action ensures strong, reliable connections are established once, while subsequent LED replacements only require simple insertion and removal operations without repeating the complex mounting process.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If threaded sleeve mounting is used for easy replacement, then the replacement is simple, but the form factor becomes bulky

Engineering Contradiction:

Improvereplacement easeVSAvoidsocket volume

Core Design Contradiction:

Ease of operationVSVolume of moving object

Solution Approach 1:

The invention replaces the threaded mechanical connection system with a simpler friction-fit or snap-fit mechanism combined with spring-loaded electrical contacts. This substitution eliminates the need for threads and nuts, significantly reducing the socket volume and allowing compact LED module replacement without bulky components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of operation

If threaded bulb socket arrangement is used, then replacement is intuitive, but the cost increases

Engineering Contradiction:

Improvereplacement easeVSAvoidmanufacturing cost

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The invention applies different qualities to different parts of the system: the socket uses simple, low-cost materials and construction for the mounting portion, while the LED assembly itself maintains its specialized optical and electrical properties. This local differentiation allows cost-effective manufacturing of the replacement mechanism without compromising LED performance.

Inventive Principle:

Principle #3Local quality

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

Facilitates cost-effective and easy replacement of LEDs in various applications, including portable lights and multi-LED fixtures, without the need for tools or heat, maintaining electrical contact and allowing for quick changes in brightness or color.

Implementation Method 1

a spring contact mechanism biased to contact the LED lamp contacts to provide electrical connection and replaceable by simple application of force

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

a clamp lock mechanism for maintaining electrical connection and replaceable by simple application of force

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS7744266B2LED socket and replaceable LED assemblies

Publication Date: 2010.06.29 IDEAL IND LIGHTING LLC

AI summary

Socket arrangements for releasably mounting LEDs and light fixtures or assemblies employing such sockets are described. The socket arrangements facilitate the replacement of LEDs to replace an original LED with a brighter replacement, to change the color of the LED, to replace a single LED with a multiple chip LED, to replace a damaged or burned out LED with a new one, or the like. In further assemblies with plural LEDs, the use of ready release sockets facilitates selective replacement of an LED or LEDs and greatly enhances the flexibility of such units.