Sheet Metal Snap 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 screws or tape, which complicates the fixation process and makes it difficult to reopen the assembly.
Innovation Solution
A metal-based support with a snap fixation element that changes configuration under applied force, allowing easy fixation and release of the light source support, reducing the need for additional components and 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 fixation element is divided into a central part and two protruding elements that can move independently. The protruding elements can be inserted through openings in the support structure and then the central part is deformed to clamp them securely, separating the insertion phase from the securing phase to reduce assembly time
Solution Approach 2:
The central part of the fixation element is designed to be deformable, allowing it to transition between a relaxed state (for easy insertion) and a clamped state (for secure fixation). This dynamic behavior eliminates the need for separate fastening operations and reduces assembly time while maintaining fixation security
2Reliability
If screws or tape are used to fixate the light module, then the fixation is secure, but extra components and tools are needed
Solution Approach 1:
The fixation element combines multiple functions into a single integrated component: the central part provides structural support and clamping force, while the protruding elements provide positioning and engagement with the support structure. This eliminates the need for separate screws, washers, or tape, reducing component count while maintaining secure fixation
Solution Approach 2:
The fixation element serves multiple purposes: it positions the light module, provides secure clamping, and enables easy release by deforming the central part. This multi-functional design replaces multiple specialized components (screws for clamping, tape for positioning) with a single versatile element
3Reliability
If screws are used to mount the PCB with LEDs, then the mounting is secure, but skilled and trained personnel are required for installation
Solution Approach 1:
The protruding elements are pre-positioned on the fixation element, and the openings in the support structure are pre-aligned. During installation, the protruding elements are simply inserted through the openings, and the central part is deformed to secure them. This preliminary arrangement of components eliminates the need for skilled alignment and fastening operations
4Ease of manufacture
If the fixation element uses a deformable central part with protruding elements, then the assembly process is simplified, but the fixation mechanism becomes more complex
Solution Approach 1:
The central part is designed with specific material properties and geometric parameters that enable it to be deformed by hand pressure while maintaining clamping force. By optimizing the thickness, material elasticity, and shape of the central part, the complex deformation behavior is achieved through simple parameter adjustments rather than complex mechanisms
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 snap fixation element enables quick and secure attachment of light source supports, simplifying the assembly process, reducing costs, and facilitating easy disassembly for repairs or component exchanges.
Implementation Method 1
a central part 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
Data Source
Figure 1A~1C
Figure 2A~2C
Figure 2D~2E
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.