Light Module Spring-Biased Contact Assembly for Wiring Error Reduction
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Solution Overview
Problem
Solid-state lighting systems with LEDs face challenges in efficient power delivery and thermal dissipation, and the assembly process is complex and time-consuming, especially in limited spaces, with multiple wires increasing the risk of mis-wiring and making replacements difficult.
Innovation Solution
A light module design featuring a base ring assembly with spring-biased power contacts and a pressure spring to create a separable power connection, integrated with a heat sink for efficient thermal dissipation, and a top cover assembly with a collar and optical component for efficient light emission and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple wires are used to connect the circuit board to the lighting fixture, then the power connection is established, but the assembly time increases and the risk of mis-wiring increases
Solution Approach 1:
The patent combines multiple wire connections into a single connector assembly. The connector integrates multiple electrical contacts and insulation housing into one unified component that connects the LED module to the driving circuit, eliminating the need for separate wire connections and reducing assembly complexity.
Solution Approach 2:
The patent segments the lighting system into modular components with integrated connectors. The LED module includes built-in connectors that are pre-assembled with the LED array, allowing for quick connection and disconnection without manual wire routing, thus reducing assembly time and minimizing wiring errors.
2Reliability
If wires are soldered between the circuit board and the fixture, then the electrical connection is secure, but the replaceability of components decreases
Solution Approach 1:
The patent employs dynamic, reversible connector designs that allow for repeated connection and disconnection without degradation. The connectors use spring-loaded contacts, bayonet mounting, or snap-fit mechanisms that maintain secure electrical connection during operation but can be easily disconnected for component replacement or repair.
3Adaptability or versatility
If a complex assembly process is used to integrate different components, then the system functionality is complete, but the manufacturing complexity increases
Solution Approach 1:
The patent implements universal connector designs and standardized mounting interfaces that can accommodate different LED module configurations and fixture types. The connectors are designed to handle multiple functions including electrical connection, mechanical mounting, and thermal management interface, reducing the number of separate components and assembly steps required.
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
This design simplifies the assembly process, reduces the risk of mis-wiring, enhances thermal management, and allows for efficient power delivery, making the system more reliable and cost-effective for various applications.
Implementation Method 1
a pressure spring positioned between the top cover assembly and the base ring assembly, the pressure spring providing a biasing force on the contact holder in a direction of the LED package to force the contact holder toward the LED package
Implementation Method 2
the power contacts being spring biased against the power terminals to create a separable power connection with the power terminals
Data Source
Figure 1~3
Figure 2
Figure 4
AI summary
A light module (210) includes a light engine (214) that has an LED package (216) having power terminals (220). A base ring assembly (230) holds the light engine (214). The base ring assembly (230) has a base ring (240) configured to be mounted to a supporting structure. The base ring (240) has a securing feature (245). The base ring assembly (230) has a contact holder (242) that holds power contacts. The power contacts are spring biased against the power terminals (220) to create a separable power connection with the power terminals (220). A top cover assembly (232) is coupled to the base ring (240). The top cover assembly (232) has a collar (260) surrounding the base ring (240). The top cover assembly (232) has a securing feature that engages the securing feature of the base ring (240) to couple the collar (260) to the base ring (240). The collar (260) has a cavity (266) and an optical component (234) is received in the cavity (266). The optical component (234) is positioned to receive light from the LED package (216) and the optical component (234) is configured to emit the light generated by the LED package (216).