Lighting Device Substrate Fixation via Elastic Padding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Light-emitting modules with deflected substrates are prone to damage during fixation due to stress concentration, which can lead to cracks, and existing solutions like using rubber inserts complicate the manufacturing process.
Innovation Solution
A lighting device design featuring a substrate holder that applies pressure to the substrate through a padding made of the same material as the sealant, which reduces stress on the substrate and prevents damage by elastic deformation, maintaining production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screws are used to fasten the substrate holder and mount together, then the light-emitting module is fixed to the mount, but stress concentrates on deflected sections of the substrate causing damage
Solution Approach 1:
A cushioning member (rubber or foam material) is introduced as an intermediary between the substrate holder and the substrate. This cushioning member absorbs and distributes the fastening stress, preventing stress concentration on deflected substrate sections while maintaining secure fixation. The cushioning member acts as a stress-distributing mediator that protects the substrate during the fastening process.
2Reliability
If a cushioning member is inserted between the substrate holder and substrate, then substrate damage is avoided, but manufacturing complexity increases
Solution Approach 1:
The cushioning member is integrated directly into the substrate holder structure, merging two components into one. The substrate holder is designed with a recess that receives and retains the cushioning member, eliminating the need for separate assembly steps. This integration maintains substrate protection while simplifying manufacturing and assembly processes.
3Reliability
If the substrate is pressed against the mount during fastening, then the light-emitting module is securely fixed, but deflected substrates are likely to crack
Solution Approach 1:
The cushioning member is pre-installed between the substrate holder and substrate before the fastening process begins. This beforehand cushioning ensures that stress is distributed evenly from the moment fastening starts, preventing stress concentration on deflected substrate sections. The cushioning member is already in position to absorb and distribute forces, protecting the substrate throughout the entire fastening process.
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 effectively prevents substrate damage during fixation by distributing pressure through the padding, ensuring high production efficiency and reliable operation regardless of substrate deflection.
Implementation Method 1
the light-emitting module is fixed to the mount by receiving pressure from the substrate holder via the padding brought into contact with a surface of the substrate holder... the padding reduces stress on the substrate and prevents damage by elastic deformation
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A lighting device pertaining to one aspect of the present invention includes a mount, a light-emitting module, and a substrate holder. The light-emitting module is mounted on a main surface of the mount, and the substrate holder covers a portion of the light-emitting module and is connected with the mount. The light-emitting module includes a substrate, a plurality of light-emitting elements, a sealant and a padding. The padding is provided on a first main surface of the substrate. The light-emitting module is mounted on the main surface of the mount such that a second main surface of the substrate comes into contact with the main surface of the mount, and the light-emitting module is fixed to the mount by pressure applied from the substrate holder via the padding brought into contact with the substrate holder. The padding is made of a same material as the sealant.