Linear Light Grounding via Insulation Piercing
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Solution Overview
Problem
Existing lighting devices, particularly LED-based systems, face challenges in safety design during assembly, requiring effort to add ground wires and ensuring electrical safety, which can lead to potential damages like fires.
Innovation Solution
A linear light apparatus design featuring a light strip with LED modules, a main bracket, a bottom holder, and a metal clip with insulation layers and thorns for easy electrical connection to ground, ensuring safety while simplifying assembly by using a U-shape metal clip with thorns to stab insulation layers for grounding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional grounding methods with ground wires are used, then electrical safety is improved, but assembly complexity and time increase
Solution Approach 1:
The patent combines the grounding function with the existing metal bracket structure by adding grounding thorns directly to the bracket. This integrates the grounding mechanism into the structural component, eliminating the need for separate ground wires and reducing assembly steps while maintaining electrical safety.
Solution Approach 2:
The metal bracket with integrated grounding thorns serves dual purposes: providing structural support and establishing electrical ground connection. The bracket itself performs the grounding function without requiring additional dedicated grounding components, allowing the system to ground itself through the existing structural element.
2Reliability
If separate ground wires are added for safety, then electrical protection is improved, but manufacturing cost and assembly time increase
Solution Approach 1:
The grounding function is merged into the metal bracket by incorporating grounding thorns directly into the bracket structure. This eliminates the need for separate ground wires and reduces the number of assembly operations required, thereby decreasing assembly time while maintaining electrical protection.
Solution Approach 2:
The metal bracket is designed to serve multiple functions: providing structural support, mounting components, and establishing electrical ground connections through integrated grounding thorns. This multi-functionality reduces the total number of components and assembly steps required.
3Reliability
If insulation layers are removed for grounding connection, then electrical connectivity is improved, but risk of electrical hazards increases
Solution Approach 1:
The grounding thorns are pre-designed with specific geometries that enable them to automatically pierce through insulation layers during the assembly process. This preliminary design ensures that the insulation is removed at the correct location and time, establishing reliable grounding connectivity while minimizing exposure to electrical hazards through controlled, intentional design.
Solution Approach 2:
The grounding thorns act as intermediaries that safely bridge the insulated metal bracket and the grounding target (such as a metal surface or ground plane). The thorns provide a controlled path through the insulation, enabling electrical connectivity while the surrounding insulation structure maintains protection in non-grounding areas.
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 design enhances safety by providing an efficient and secure grounding mechanism, reducing the risk of electrical hazards during assembly and operation, while maintaining a compact and cost-effective assembly process.
Implementation Method 1
The metal clip is pressed to one side wall for the first thorn to stab the second insulation layer to electrically connect the bottom holder and the metal clip. The second thorn stabs the first insulation layer for the metal clip to be electrically connect to the first metal part of the main bracket.
Data Source
AI summary
A linear light apparatus includes a light strip, a light passing cover, a main bracket, a bottom holder and a metal clip. The light strip having an elongated substrate mounted with LED modules. The main bracket holds the light strip for the LED modules emitting a light passing through the light passing cover. The metal clip has a first thorn and a second thorn. The metal clip is pressed to one side wall for the first thorn to stab a second insulation layer to electrically connect the bottom holder and the metal clip. The second thorn stabs a first insulation layer for the metal clip to be electrically connect to the first metal part of the main bracket.