Tamper-Proof Light Emitting Module Manufacturing
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Solution Overview
Problem
Traditional light emitting modules are either modular and tamperable, leading to potential breakage and reduced internal space, or tamper-proof but untestable before packaging, resulting in waste and suboptimal water resistance.
Innovation Solution
A method of manufacturing a tamper-proof light emitting module by pre-assembling and testing the module with removable fasteners, then replacing them with breakaway fasteners that become permanently fixed, ensuring the module is operable and secure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If modular design is used to allow user disassembly and component replacement, then ease of repair is improved, but device complexity increases and internal space decreases due to additional housing structures
Solution Approach 1:
The housing is divided into multiple components (first housing component, second housing component, third housing component) that can be separately assembled and disassembled. This segmentation allows users to access and replace internal components while maintaining a manageable structural complexity through standardized interfaces and fastening mechanisms.
2Manufacturing precision
If modular design with removable fasteners is used to allow testing before final assembly, then manufacturing precision is improved, but device complexity increases due to multiple fastening mechanisms
Solution Approach 1:
The housing components are assembled with removable fasteners during the testing phase before final assembly. This preliminary action allows the light emitting module to be tested for functionality and waterproofing while still accessible, and only after successful testing are the breakaway fasteners activated to create the final tamper-proof configuration.
3Reliability
If tamper proof design with permanent sealing is used to improve water resistance, then reliability is improved, but ease of repair worsens as users cannot access internal components
Solution Approach 1:
The housing structure incorporates different types of fasteners in different locations and at different stages: removable fasteners for initial assembly and testing, and breakaway fasteners for final tamper-proof sealing. This local differentiation allows the same housing structure to provide both accessibility during manufacturing and permanent protection during use.
4Reliability
If breakaway fasteners are used to create tamper proof configuration, then reliability is improved, but device complexity increases due to the breakaway mechanism
Solution Approach 1:
The fastener design incorporates a breakaway head mechanism that changes its structural parameter from removable to permanent through a controlled breaking action. The fastener body remains intact and continues to provide fastening function, while the head portion is designed to break off at a predetermined point, transforming the fastener from an accessible component to a tamper-proof element.
Data Source
AI summary
The present disclosure relates to a method of manufacturing a tamper proof light emitting module comprising the steps of (a) pre-assembling the light emitting module into a testing configuration including a housing and one or more light emitting elements mounted within the housing, the housing including first and second housing components connected together using at least one removable fastener connecting the first and second housing components; (b) testing the light emitting module to confirm the light emitting elements are operable; (c) after step (b), removing the removable fastener; (d) replacing the removable fastener removed in step (c) with at least one breakaway fastener; and (e) tightening the breakaway fastener(s) until the head of the breakaway fastener(s) breaks off so that the breakaway fastener(s) is no longer removable, thereby creating a final, tamper proof configuration of the light emitting module.