Lighting Device Contact Carrier Sub-Assembly
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Solution Overview
Problem
The complexity and cost of manufacturing lighting assemblies increase with the number of interconnected components and soldering steps, necessitating a reduction in components and manufacturing steps to simplify the process.
Innovation Solution
A lighting device design featuring a contact carrier sub-assembly divided into substantially identical sections with contacts extending from the base to the light emitting end, providing a continuous electrically conductive path without additional components, secured through snap-fit connections and eliminating the need for adhesives and multiple soldering steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple interconnected components and soldering steps are used to assemble lighting assemblies, then reliable electrical connections are achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines multiple separate components (contact carrier, contacts, and support structure) into an integrated single-piece molded component. This merging eliminates the need for separate assembly steps and reduces manufacturing complexity while maintaining reliable electrical connections through the integrated design.
Solution Approach 2:
The single-piece molded component performs multiple functions simultaneously: it provides structural support, carries electrical contacts, provides mechanical attachment points, and ensures electrical connectivity. This multi-functionality reduces the total number of components needed while maintaining system reliability.
2Reliability
If multiple soldering steps are used to electrically couple components, then reliable electrical connections are achieved, but manufacturing time and cost increase
Solution Approach 1:
The patent combines multiple soldered electrical connections into a single integrated molded component where electrical connectivity is achieved through the molding process itself rather than through multiple separate soldering steps. This dramatically improves manufacturing efficiency while maintaining connection reliability.
Solution Approach 2:
The patent replaces the mechanical/electrical joining process (soldering) with a molding process that creates integral electrical connections. The molded component inherently provides electrical pathways through its structure, eliminating the need for separate soldering operations.
3Strength
If adhesives are used to secure housing components together, then structural integrity is achieved, but manufacturing cost and time increase
Solution Approach 1:
The patent merges the contact carrier, contacts, and support structure into a single molded piece that is then integrated into the housing as one component rather than requiring separate adhesive bonding of multiple small parts. This reduces manufacturing steps while maintaining structural integrity.
Solution Approach 2:
The patent segments the complex assembly of multiple small electrical components into a single manageable molded component unit. This segmentation allows the assembly to be treated as one piece rather than multiple components requiring adhesive bonding, simplifying manufacturing while maintaining structural strength.
Data Source
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AI summary
A lighting device (100) includes an outer assembly (128), a light emitting device (102), and a contact. The outer assembly (128) extends between a base end (108) and a light emitting end (106). The outer assembly (128) includes a contact carrier sub-assembly (118) that extends from the base end (108) to an outer end disposed proximate to the light emitting end (106). The light emitting device (102) is disposed proximate to the light emitting end (106) of the outer assembly (128). The contact is held in the contact carrier sub-assembly (118) and extends from the base end (108) of the outer assembly (128) to the outer end of the contact carrier sub-assembly (118). The contact is electrically coupled with the light emitting device (102) to provide a continuous electrically conductive path from the base end (108) of the outer assembly (128) to the outer end of the contact carrier sub-assembly (118). The contact is configured to supply electric current to the light emitting device (102).