Snap-Fit Bracket Light Module for Faster LED Assembly
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Solution Overview
Problem
The assembly efficiency of existing LED bracket lights is hindered by a complex production process, including multiple assembly steps, limited space for welding, and accumulation of AC input wires.
Innovation Solution
An easily-assembled bracket light module design featuring snap-fit assemblies between the light tube, plugs, and end caps, allowing for rapid assembly and eliminating the need for welding operations through a screwless snap-fit design and shared substrate for the light panel and driver.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding and multi-step assembly processes are used, then connection strength is improved, but assembly time and production complexity increase
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a snap-fit mechanical connection system. The snap-fit assembly uses elastic deformation of plastic materials to create secure connections without heat or complex machinery, thereby reducing assembly time while maintaining connection strength through the elastic recovery force of the snap-fit components.
Solution Approach 2:
The bracket light is divided into modular components (light tube assembly, end cap assembly, driver assembly) that can be independently manufactured and then quickly assembled together using snap-fit connections. This segmentation allows parallel production of components and simplifies the final assembly process, reducing overall production time while maintaining structural integrity.
2Reliability
If multiple assembly steps and welding operations are required, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex welding operations with simple snap-fit mechanical connections that are easier to control and less prone to human error. The snap-fit design provides inherent alignment features and self-centering mechanisms that ensure consistent, reliable connections without requiring skilled welders or complex positioning fixtures.
Solution Approach 2:
The patent combines multiple functions into integrated components. For example, the end cap assembly integrates both structural support and electrical connection functions, while the snap-fit mechanism simultaneously provides both mechanical attachment and alignment. This merging reduces the number of separate assembly steps and simplifies the overall process while maintaining reliability.
3Reliability
If AC input wires are accumulated and managed traditionally, then electrical connectivity is ensured, but space occupation and assembly complexity increase
Solution Approach 1:
The patent nests the AC input wires and electrical connections within the hollow interior cavity of the plug component. The wires are routed through predefined pathways inside the plug body, utilizing the empty space that would otherwise be unused. This nesting approach consolidates wire management into the existing component structure, reducing external space requirements and simplifying assembly.
Solution Approach 2:
The plug component is designed with multi-functionality: it serves as both a structural mounting element and an integrated wire management system. The hollow cavity of the plug simultaneously provides structural support, houses the electrical connections, and manages the AC input wires, thereby eliminating the need for separate wire management components and reducing overall space occupation.
Data Source
AI summary
An easily-assembled bracket light module is provided, including a light tube assembly, plugs, and an end cap assembly. The plugs are provided with a first snap-fit assembly and a second snap-fit assembly. The light tube assembly is provided with a third snap-fit assembly, which is matched with the first snap-fit assembly to connect the light tube assembly to the plugs. The end cap assembly is provided with a fourth snap-fit assembly, which is matched with the second snap-fit assembly to connect the end cap assembly to the plugs. The plugs are respectively connected to the light tube assembly and the end cap assembly via a snap-fit, allowing for rapid assembly, high efficiency, and an enhanced user experience. Meanwhile, an input end cap and an output end cap both adopt a screwless snap-fit design for quick assembly and compatibility, and this design meets the certification requirements for the pull force test.