LED Support Clip Spring Jams Mounting
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Solution Overview
Problem
The existing methods for mounting LED light modules on aluminum tubing in sign shops face adhesion issues due to oily residues, leading to inefficient attachment and potential detachment when temperatures rise, necessitating the use of adhesives or screws, which are time-consuming and inconvenient.
Innovation Solution
The development of an LED support clip with spring tension jaws that clamps onto the tubing without adhesives or screws, allowing for easy and secure attachment and repositioning of LED light modules, using materials like plastics or metals with specific geometries and angles to ensure clamping force and ease of removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If double-sided adhesive tape is used to mount LED light modules on aluminum tubing, then the mounting process is simple, but the adhesion fails when temperatures rise due to oily residues on the aluminum surface
Solution Approach 1:
The patent introduces an intermediary mounting mechanism consisting of a mounting bracket with clamping jaws that physically grip the aluminum tubing. This mechanical intermediary system transfers the mounting function from direct adhesive contact to mechanical engagement, eliminating the adhesion failure issue while maintaining ease of installation through snap-fit engagement.
Solution Approach 2:
The patent replaces the chemical adhesion mechanism (adhesive tape) with a mechanical clamping mechanism. The mounting bracket uses spring-loaded or elastic clamping jaws that mechanically grip the aluminum tubing, substituting the chemical bonding process with a physical mechanical system that is not affected by temperature-induced adhesion failure.
2Reliability
If adhesives or screws are used to secure LED light modules, then the attachment becomes reliable, but the mounting process becomes time-consuming
Solution Approach 1:
The mounting system is segmented into separate functional components: a mounting bracket that attaches to the aluminum tubing, and LED light modules that attach to the bracket. This segmentation allows for modular assembly where the bracket pre-attaches to the support structure, and modules are then quickly snapped into place, reducing overall mounting time while maintaining reliability.
Solution Approach 2:
The mounting bracket is designed to be pre-assembled and pre-attached to the aluminum tubing before the LED light modules are installed. This preliminary action of securing the bracket first creates a ready-to-receive platform, allowing modules to be quickly mounted without requiring simultaneous complex operations, thereby reducing mounting time while ensuring reliable attachment.
3Productivity
If adhesive tape is used for mounting, then the process is quick, but the LED modules may detach when temperatures rise
Solution Approach 1:
The mounting mechanism utilizes elastic deformation of the clamping jaws as a key parameter. The spring-loaded or elastic components deform under mounting pressure and then return to their original shape, creating a stable mechanical lock that is not affected by temperature changes. This elastic parameter change provides both quick mounting and temperature-stable stability.
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
Enables faster, more convenient, and secure mounting of LED light modules without adhesives or screws, allowing for easy replacement and repositioning, improving the efficiency and reliability of LED lighting systems.
Implementation Method 1
The LED support clip is made from any material that is sufficiently elastic such that the LED support clip will clamp onto a support with sufficient force to be immobile during use
Data Source
AI summary
An LED support clip enables mounting of light-emitting diode (LED) modules onto support elements which may be pre-existing, such as tubing, while avoiding problems with current mounting methods. One or more LED light modules may be clamped into the LED support clip without the need for adhesives or screws, thereby forming an LED light assembly. One or more LED light assemblies may be clamped onto the support element. The LED support clip may comprise multiple clamps configured with spring tension jaws designed into the manufacturing process of the LED support clip. Support elements may be oriented horizontally, vertically or at various angles and may have a variety of cross-sectional shapes, including: square, triangular, rectangular, pentagonal, hexagonal, “I”-shaped, “L”-shaped, and round, over a wide cross-sectional dimension range.