Integrated Metal Frog Fixation for Fast LED PCB Mounting
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Solution Overview
Problem
Current methods for mounting rigid PCBs with LEDs in luminaires require skilled labor, are time-consuming, and involve high costs due to the need for additional components and tools, with complex and difficult re-opening processes.
Innovation Solution
A metal-based support system with a snap fixation element that allows easy attachment and detachment of light source elements, utilizing a central part that changes configuration under force, enabling quick and secure fixation and release without additional tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screws or tape are used to fixate the light module to the luminaire, then the fixation is secure, but the assembly time increases and skilled labor is required
Solution Approach 1:
The invention extracts the fixation function from separate components (screws, tape) and integrates it into the support structure itself through the frog element, which is formed as an integral part of the support. This eliminates the need for additional fixation components and reduces assembly complexity.
Solution Approach 2:
The frog element provides self-aligning and self-fixating functionality through its geometric design with protrusions and recesses that automatically engage when the support is positioned on the base profile, eliminating the need for manual alignment and fixation operations.
2Reliability
If screws or tape are used to fixate the light module, then fixation is achieved, but extra components and tools are needed increasing costs
Solution Approach 1:
The invention merges the support structure and fixation mechanism into a single integrated component. The frog element with its protrusions and recesses is formed as an integral part of the support, combining structural support and fixation functions in one element.
Solution Approach 2:
The support structure serves multiple functions: it provides mechanical support for the light module and simultaneously provides fixation through the integrated frog element. This multi-functional design eliminates the need for separate fixation components.
3Reliability
If screws are used to fixate the light module, then fixation is secure, but the re-opening process becomes complicated and time-consuming
Solution Approach 1:
The frog element is designed with elastic properties that allow it to dynamically change state between locked and unlocked configurations. The protrusions can be elastically deformed to release the connection and return to their original position to re-establish fixation, enabling easy reversible mounting.
4Manufacturing precision
If skilled personnel are used for assembly, then correct installation is achieved, but assembly costs increase
Solution Approach 1:
The frog element provides self-aligning functionality through its geometric design, where the protrusions and recesses automatically guide and position the support relative to the base profile during assembly. This self-positioning capability eliminates the need for skilled alignment operations.
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 solution reduces assembly time and costs, simplifies the fixation process, and allows for easy re-opening and maintenance of light modules, improving efficiency and reducing the risk of incorrect installation.
Implementation Method 1
a central part (410) which is configurable in a first configuration and in a second configuration, different from the first configuration, wherein a change from one configuration to the other can be effected by applying a force on the central part (410)
Data Source
AI summary
The invention provides a metal-based support (100) for a lighting element (200), wherein the lighting element (200) comprises a light source support (300) and a light source (10) functionally coupled to the light source support (300), wherein the metal-based support (100) comprises a metal body (140) and a fixation element (400) for fixating the light source support (300) to the metal-based support (100), wherein at least part of the fixation element (400) is part of the metal body (140), wherein the fixation element (400) comprises a central part (410) which is configurable in a first configuration and in a second configuration, different from the first configuration, wherein a change from one configuration to the other can be effected by applying a force on the central part (410), wherein the fixation element (400) comprises two protruding elements (420) configured extending from the central part (410) in both configurations of the central part (410), wherein terminal parts (421) of the respective protruding elements (420) have a first mutual distance (d1) in the first configuration of the central part (410) and a second mutual distance (d2) in the second configuration of the central part (410), wherein the first mutual distance (d1) is larger than the second mutual distance (d2), and wherein the fixation element (400) is configured to receive the light source support (300) in the first configuration and to fixate the light source support (300) to the metal-based support (100) in the second configuration.