Modular LED Circuit Boards for Variable Length Fixtures
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Solution Overview
Problem
Existing LED light fixtures face challenges in accommodating varying lengths and shapes due to the need for multiple product variations, leading to complex inventory management and increased costs.
Innovation Solution
A modular design featuring a master circuit board and interchangeable LED boards of standard lengths and shapes, allowing for flexible combinations to produce light fixtures of different lengths and shapes using a limited number of circuit board units, with features like AC-DC rectifiers, linear AC drivers, and control options for lighting characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple alternative models with different dimensions are produced to satisfy customer demand, then adaptability is improved, but device complexity and inventory management complexity increase
Solution Approach 1:
The light fixture is divided into modular components: a master circuit board and multiple interchangeable LED circuit boards of different lengths and shapes. This segmentation allows customers to configure fixtures of various dimensions by selecting different LED board combinations, achieving adaptability without producing entirely different models. The master board remains standardized while the LED boards provide the variation needed for different applications.
Solution Approach 2:
The master circuit board is designed as a universal component that can interface with multiple types of LED circuit boards through standardized connections. This multi-functionality allows a single master board design to support various fixture configurations, reducing the number of unique SKUs needed while maintaining the ability to satisfy diverse customer requirements for different lengths and shapes.
2Adaptability or versatility
If multiple alternative models with different dimensions are produced to satisfy customer demand, then adaptability is improved, but manufacturing and inventory costs increase
Solution Approach 1:
By segmenting the fixture into a standardized master board and interchangeable LED boards, the manufacturing process is simplified. The master board can be produced in high volume as a single SKU, achieving economies of scale. Different LED boards are manufactured separately and then assembled into the master board configuration, reducing the need to manage complex multi-component assemblies for each model variant.
Solution Approach 2:
The universal master circuit board design allows a single manufacturing process to produce a core component that can be used across multiple fixture configurations. This reduces tooling costs, setup time, and inventory carrying costs compared to producing entirely different models, while still enabling customization through the selection of different LED board combinations.
3Adaptability or versatility
If a modular design with interchangeable LED boards is used, then adaptability is improved, but connection complexity increases
Solution Approach 1:
A universal connection interface is designed on both the master board and LED boards, enabling standardized mating connections. This universal interface simplifies the assembly process by providing consistent mechanical and electrical connection protocols, reducing the complexity that would otherwise arise from custom interfaces for each board type. The standardized connections allow for easy interchangeability while maintaining reliable electrical connectivity for power and control signals.
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 modular design simplifies inventory management by supporting multiple lengths and shapes with fewer SKUs, offering customizable lighting options and improved efficiency through adjustable current and color settings, while reducing inventory complexity.
Implementation Method 1
An AC-DC rectifier receives the AC power and drives direct-current (DC) power
Implementation Method 2
The linear AC drivers drive an LED array
Implementation Method 3
light emitting diode (LED) arrays
Data Source
AI summary
A light fixture having master circuit boards and one or more LED circuit boards connectable in various alternative combinations for light fixtures having alternative lengths, the master board including a switch and AC-DC rectifier and the LED boards including linear AC drivers and one or more LED arrays, the switch on the master board controlling the linear AC drivers on the LED board or boards.