LED Track Light Module Snap-Assembly
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Solution Overview
Problem
There is a need for track lighting systems that can be efficiently manufactured at a low cost and easily installed while providing reliable operation over years, as LED lighting becomes more prevalent.
Innovation Solution
A track light module with a printed circuit board carrying an LED, a second housing with electrical conductors that extend into a low-voltage track for power contact, and a connector to attach the housings together, allowing for quick assembly without separate fastening devices, ensuring structural integrity and cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional track lighting assemblies are used, then reliable operation is achieved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent combines multiple separate components (housing, electrical contacts, fastening mechanisms, and mounting interfaces) into a single integrated track lighting assembly. This merging eliminates the need for separate fastening devices and reduces the number of assembly steps, thereby improving manufacturing efficiency while maintaining reliable operation.
Solution Approach 2:
The track lighting assembly is designed with multi-functional elements where the housing serves both structural and electrical functions, the electrical contacts provide both connection and alignment functions, and the fastening surfaces integrate mounting capabilities directly into the housing structure. This multi-functionality reduces the overall number of components needed.
2Strength
If complex fastening devices are used, then structural integrity is improved, but assembly time and manufacturing cost increase
Solution Approach 1:
The track lighting assembly incorporates self-aligning electrical contacts and self-fastening surfaces that automatically position and secure components during assembly. The electrical contacts are designed to naturally align with the track conductors, and the fastening surfaces engage automatically when the housing is mounted, eliminating the need for separate fastening operations and reducing assembly time while maintaining structural integrity.
3Ease of repair
If multiple separate components are used, then ease of repair is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
While the patent integrates many components into a single assembly, it maintains segmentation at the module level, allowing the entire track lighting assembly to be replaced as a single unit or with modular sub-components. This approach balances the benefits of integration (reduced part count) with the advantages of segmentation (ease of replacement), as defective modules can be quickly swapped without disassembling the entire system.
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
The solution enables efficient, cost-effective manufacturing and reliable operation of track lighting systems with a simple snap-together assembly, maintaining structural integrity over a long operating life.
Implementation Method 1
a printed circuit board that carries an LED
Data Source
AI summary
A track light module for use with a low-voltage track carrying a pair of elongated conductors transversely spaced from each other and accessible through a longitudinal slot in the track. The module includes a first housing that contains a printed circuit board carrying an LED and forming an aperture permitting light from the LED to be radiated beyond the first housing. A second housing carries a pair of electrical conductors adapted to extend into the low-voltage track to make contact with the conductors within the track. The second housing also includes surfaces for fastening the second housing to the track when the second housing and the track are moved relative to each other. A pair of electrical contacts on the printed circuit board contact the conductors carried by the second housing and thereby receive electrical power for the LED. A connector attaches the first and second housings together.