Solar Lighting Module With Conductive Springs

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Solution Overview

Problem

Manual soldering of electrical connections between solar panels and integrated circuit boards in garden lamps is labor-intensive, time-consuming, and costly, hindering efficient assembly and production.

Innovation Solution

A solar lighting module design featuring conductive springs that elastically connect the solar panel and integrated circuit board, eliminating the need for manual soldering by using perforations and corresponding conductive terminals, allowing for easy and quick electrical connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual soldering is used to connect electrical wires between solar panel and integrated circuit board, then reliable electrical connection is achieved, but assembly time and labor cost increase significantly

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidassembly efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the manual soldering process (thermal/mechanical system) with a mechanical pressing system using conductive springs. The conductive springs are pressed against the conductive terminals to establish electrical connections, eliminating the need for soldering irons, heat, and manual dexterity while maintaining reliable electrical contact between the solar panel and integrated circuit board.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The conductive springs are designed to automatically establish electrical connections when the solar lighting module is assembled. The springs self-adjust to the conductive terminals through elastic deformation, creating reliable electrical contact without requiring operator intervention for each connection point. This self-service mechanism significantly reduces assembly time and labor requirements.

Inventive Principle:

Principle #25Self-service

2Reliability

If manual soldering is used for electrical connections, then stable electrical contact is achieved, but manufacturing cost and processing time increase

Engineering Contradiction:

Improveelectrical contact stabilityVSAvoidprocessing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The conductive terminals are pre-formed on the solar panel and integrated circuit board before assembly. The conductive springs are pre-positioned in the circuit board, and during final assembly, they automatically align and contact the pre-formed terminals. This preliminary preparation eliminates the need for time-consuming soldering operations during the assembly process while ensuring stable electrical contact.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the connection method from thermal (soldering) to mechanical (spring pressure). By changing the fundamental parameter of how electrical connections are established, the process eliminates the time-consuming heating and cooling cycles of soldering while maintaining reliable electrical contact through the elastic force of the conductive springs.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If conductive springs are used for electrical connection, then assembly efficiency is improved, but connection complexity increases

Engineering Contradiction:

Improveassembly speedVSAvoidconnection structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent merges multiple functions into the conductive springs: they provide both the electrical conduction path and the mechanical connection force simultaneously. The springs are integrated into the circuit board structure, combining the terminal connection function with the mounting structure, thereby simplifying the overall design despite the improved assembly efficiency.

Inventive Principle:

Principle #5Merging (Combining)

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 design significantly reduces assembly difficulty, saves time and resources, and enhances production efficiency by enabling quick and convenient electrical connections without manual wire soldering.

Implementation Method 1

the conductive spring elastically abuts the conductive terminal of the bottom side of the solar panel

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

a solar panel for generating electric power

Methodology Applied

Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Data Source

PatentUS12078318B1Solar lighting module for garden lamps

Publication Date: 2024.09.03 METROMAX AMERICA CORPORATION

AI summary

A solar lighting module for garden lamps detachably mounted onto the top end of a hollow lamp column of a garden lamp includes a top with an upper casing of a solar panel, at least one light emitting element and an integrated circuit board (PCBA) of a battery fixed in the upper casing, and a multiple of conductive springs installed on the integrated circuit board and passed upwardly through the top of the upper casing and a conductive terminal of the solar panel for an electrical connection to achieve the effect of quick assembly.