Modular Lighting System With Segmented PCB Modules
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Modern lighting systems require a complete new design for each size and function, leading to complex and costly part management, assembly, and storage due to the need for specialized PCBs, LEDs, and optical components, which increases production costs and time.
Innovation Solution
A modular lighting system comprising a control PCB and LED modules, where LEDs are preassembled on module PCBs with protective features, allowing for easy handling and connection via module interfaces, enabling flexible assembly and reduced part variability across different lighting systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a complete new lighting system design is created for each size and function, then the lighting system can meet specific functional requirements and legal requirements, but part management becomes very complex and expensive with high storage and handling costs
Solution Approach 1:
The lighting system is divided into separate functional modules: LED modules with optical components, control modules with PCBs, and housing modules. Each module can be independently designed, manufactured, and managed, yet combined to create complete lighting systems for different applications. This segmentation allows standardization of individual modules while maintaining versatility in system configuration.
Solution Approach 2:
Standardized modules are designed with universal interfaces and mounting mechanisms that allow them to be used across multiple lighting system configurations. For example, LED modules can be integrated into different housing types and controlled by various control modules, enabling the same components to serve multiple functions and applications.
2Adaptability or versatility
If specialized PCBs, LEDs, and optical parts are designed for each lighting system type, then the lighting system can be optimized for specific functions, but assembly becomes very complex and time-consuming
Solution Approach 1:
Modules are pre-assembled and pre-tested before integration into the complete lighting system. LED modules come pre-equipped with optical components and electrical connections, and control modules are pre-configured with PCBs and circuitry. This preliminary preparation significantly reduces on-site assembly time and complexity.
Solution Approach 2:
Multiple functional components are merged into integrated modules. For example, LED elements, optical lenses, reflectors, and electrical connections are combined into single LED modules, while control circuits, power management, and sensors are integrated into control modules. This merging reduces the number of separate assembly steps required.
3Adaptability or versatility
If complete new designs are created for each lighting system, then specific lighting functions and light distribution can be achieved, but production costs increase due to complex manufacturing processes
Solution Approach 1:
The manufacturing process is segmented into independent module production lines. Each module type (LED modules, control modules, housing modules) can be manufactured separately using standardized processes, allowing for economies of scale and reduced tooling costs compared to producing complete custom systems for each application.
Solution Approach 2:
Standardized modules serve multiple product lines and applications, amortizing the manufacturing cost across larger production volumes. The same LED module design can be used in different housing configurations and control setups, reducing the need for expensive custom tooling and setup for each product variant.
Data Source
AI summary
A modular lighting system and method having a control PCB, an LED and a housing with a housing base. The LED is attached to a module PCB, wherein the LED and the module PCB are part of an LED module, wherein the module PCB of the LED module is electrically connected to the control PCB.