Snap-Fit LED Assembly
Modern LED lighting systems require precise assembly of multiple components - from LED arrays and heat sinks to optical elements and electrical connections. Current manufacturing processes often involve complex manual steps, with assembly times averaging 12-15 minutes per fixture and defect rates reaching 3-5% due to connection errors and misalignment.
The fundamental challenge lies in simplifying assembly while maintaining precise optical alignment, thermal management, and reliable electrical connections across diverse lighting applications.
This page brings together solutions from recent research—including substrate-joining techniques that eliminate connectors, T-shaped contact designs for universal LED compatibility, optical arrays with integrated electrodes, and modular socket-based systems. These and other approaches focus on reducing assembly complexity while ensuring consistent performance in commercial and industrial lighting products.
1. Light-Emitting Device with Overlapping Flexible and Rigid Substrates and Conductive Joining Member
NICHIA CORPORATION, 2022
A light-emitting device designed to prevent cracks in solder joints between substrates in LED displays while reducing the number of connectors. The device features two substrates: one flexible and one rigid. At one end, the flexible substrate overlaps the rigid substrate without covering the wiring patterns. An electrically conductive joining member spans across the wiring patterns to connect the substrates. This design enables flexible arrangement and prevents solder joint cracks.
2. Modular Polygonal Light Board with Integrated LED, Driver, and Power Components
SHENZHEN WITOP TECH CO LTD, SHENZHEN WITOP TECHNOLOGY CO LTD, 2021
An intelligent full-color light board that can be easily spliced together to create customized lighting configurations. The light board has a polygonal housing containing an LED light board, PCB driver board, and power module. The driver board has a LED drive control chip, current limiting resistor, decoupling capacitor, and filter capacitor connected to the power supply. The LED board, driver board, and power module are all mounted on the housing. This modular design allows individual components to be swapped, added, or removed as needed to customize the light board size, color output, and connectivity.
3. Light-Emitting Device with Overlapping Flexible Substrates and Conductive Joining Member
NICHIA CORPORATION, 2021
A light-emitting device with a cost-effective substrate joining structure that allows for flexible substrate arrangement. It consists of a first flexible substrate with mounted light-emitting elements and a second substrate. The first substrate overlaps part of the second substrate without covering its wiring. An electrically conductive joining member bridges the wiring patterns of both substrates. This design eliminates the need for connectors or adhesives, reducing manufacturing complexity and costs.
4. LED Luminaire Assembly with Replaceable Modules, Concavo-Convex Lenses, and Integrated Thermal Management
Eaton Intelligent Power Limited, 2020
High intensity LED luminaire assembly with improved thermal management, serviceability, and glare reduction. The assembly has replaceable LED modules with concavo-convex lenses for glare reduction. The modules are thermally connected to a heatsink housing. The power supply is separately housed with cooling. This allows independent replacement of modules. The power supply has circuitry for constant current and pulse width modulation dimming. It also has a thermal insulator between the power supply and LED modules. The assembly can be mounted at multiple angles.
5. LED Illumination Apparatus with Customizable LED and Optical Element Arrays Featuring Integrated Electrical Connectivity
Optovate Limited, 2020
An LED-based illumination apparatus designed for efficient, directionally controlled lighting features reduced manufacturing complexity. It comprises an array of custom optical elements, such as lenses, aligned with a separate array of LEDs. The optical elements focus and direct the light emitted by the LEDs. The optical array includes electrodes for electrical connections to the LEDs. LEDs are initially formed in a monolithic array but are selectively removed and transferred onto a substrate to create a customized LED array with specific compositions and spacings. This custom array is then assembled with the optical array, allowing for precise configuration and alignment. Techniques like selective removal from the monolithic array facilitate this customization, while the optical array ensures proper electrical contact with the LEDs.
6. LED Holder with Base and T-Shaped Contact Section for Versatile CoB-LED Pad Connectivity
TE Connectivity Nederland BV, 2019
Low-cost, small-sized holder for an LED that can easily contact and mount a variety of different CoB-LEDs having contact pads in different locations. The holder includes a base, a contact, and a T-shaped contact section. The contact is connected to electrical wiring and has a receiving section to connect to a cable. The base holds the contact and exposes the T-shaped contact section in a receptacle that receives the LED board. This allows the T-shaped contact to electrically contact a pad on the LED board.
7. LED Light Board with Integrated Component Mounting and Direct Heat Dissipation Structure
Xiamen Sankun Electronic Technology Co., Ltd., 2019
LED light board with improved heat dissipation and simplified assembly compared to traditional LED lamps. The board has the LED components like beads and driving components like diodes, resistors, etc directly mounted on the light board itself instead of separate lamp and circuit boards. This allows better heat dissipation from the LEDs. The light board and circuit board are connected via plugs and fixed together. The power connections are made using wires on the light board, which simplifies assembly compared to separate boards with terminal connections.
8. Illumination Apparatus with Separately Formed Optical and Light-Emitting Element Arrays for Aligned Light Direction
Optovate Limited, 2019
An illumination apparatus that provides a highly efficient, compact, and customizable lighting solution. The apparatus involves an array of separately formed optical elements and a separately formed array of light-emitting elements. The optical element array contains reflective or refractive elements that direct light emitted by the light-emitting elements. The optical element array also has electrodes to electrically connect to the light-emitting elements. The optical and light-emitting element arrays are assembled with alignment so each light-emitting element is positioned at an input surface of an optical element. This enables the separately formed light-emitting array to be customized and optimized independently from the optical elements.
9. Modular Lamp with Replaceable Planar Semiconductor Lighting Elements and Multi-Sided Socket Connections
Ulrich Spintge, Karsten Diekmann, Britta Goeoetz, 2019
Modular lamp design with easily replaceable planar semiconductor lighting elements that can be mounted in sockets. The lamp consists of an illuminant with a planar LED lighting surface that can be inserted into a socket. The socket provides the electrical and mechanical connection to power the illuminant. Multiple illuminants can be inserted into adjacent sockets to create a larger common illumination surface. The sockets can have connections on multiple sides for flexible wiring and shorted supply connections to simplify electrical connections.
10. Light-Emitting Device with Overlapping Substrates and Single Conductive Joining Member
NICHIA CORPORATION, 2019
A light-emitting device with a simplified, cost-effective structure using overlapping substrates and a joining member. The device has two overlapping substrates with wiring patterns and light-emitting elements. The substrates are partially overlapped with the first substrate overlapping a portion of the second substrate. An electrically conductive joining member is positioned across the wiring patterns. This configuration allows the substrates to be connected with just one joining member instead of multiple connectors.
11. LED Light Fixture with Detachable Modules and Sliding Power Connector Interface
KMW INC., 2018
LED light fixture with detachable modules that makes it easy to replace them when needed or add/remove modules to adjust brightness. The fixture has a frame with a power connector. The LED module has a connector that slides into the frame and connects to the power connector. This allows the module to be quickly attached/detached for maintenance or to customize brightness by adding/removing modules.
12. Modular LED Lighting System with Interchangeable Boards for Customizable White Light Color Temperature
FINELITE INC., 2018
Modular, interchangeable LED lighting system with customizable white light color temperature. The system uses interchangeable modular LED boards that can be mixed and matched to create unique lighting configurations. The modular boards have arrays of LEDs, and the system allows independent control of the LED boards to adjust color temperature and intensity. A control unit coordinates the boards to reach target color temperatures. The system enables tunable white light by combining yellow-white and blue-white LED sets. It also supports dimming and ambient light compensation. The modular, interchangeable boards enable versatile lighting setups and customization.
13. Two-Piece Connector with Spring-Loaded Contact Pads for Screwless LED Module Retention and Electrical Connection
SMK Corporation, 2018
A connector for holding and electrically connecting an LED module substrate without screws. It uses a two-piece cover system. Closing the upper cover piece over the lower piece clamps the LED module in between. The upper cover has spring-loaded contact pads that make electrical connection with the module's contact pads. The clamping action of closing the covers holds the module securely in place and establishes electrical contact. This eliminates the need for screws and provides reliable electrical connection to the module.
14. Modular LED Lighting Fixture with Integrated Power and Control Signal Separation for Individual Lamp Control
Yuyoung Eleccom, 2018
LED lighting fixture that allows easy assembly of multiple block-type LED lamps and individually controlling each lamp using a single AC power line. The fixture separates power and control signals received through the AC line, converts the power to suitable voltage for the LEDs, and transmits it to the lamps. The control signal is processed and sent to the lamps to independently control each LED. This enables simple assembly of block lamps without separate connections and allows flexible configuration of multiple lamps with individual control.
15. Modular OLED Light Source with Spring Biased Engagement Claws and Automatic Holding Mechanism
PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD., 2018
A modular organic light emitting diode (OLED) light source and fixture that allows easy installation and prevents OLED unit from falling out. The light source unit attaches to the socket using spring biased engagement claws. The socket has a holding mechanism that keeps the claws disengaged when the OLED unit is not present. When the OLED unit is inserted, the holding mechanism releases the claws to engage and hold the unit in place.
16. LED Light Source Component with Magnetic Snap-Fit Modules
GOLDP ELECTRIC APPLIANCE CO LTD, 2017
An LED light source component with improved convenience and ease of assembly compared to conventional designs. The component has an LED driving module and a connected light source module. Both modules have magnets to allow them to snap together and be easily assembled without screws or locks. The magnets also allow the modules to be easily separated for maintenance or replacement. This avoids the need for screws, segments, or locks that make replacing components inconvenient in traditional designs.
17. LED Lighting Assembly with Centralized Control Board and Series-Connected Multi-Color Modules
SHENZHEN EASTFIELD LIGHTING CO LTD, 2017
LED lighting assembly with multiple color LED modules controlled by a single board for simplicity, cost reduction, and intelligence. The assembly has a central control board that connects to the main LED fixture and multiple LED modules with different color temperatures. The control board has switches to turn on/off the main LED and each module separately. This allows dimming and color mixing without needing separate circuits for each module. A processor can also adjust brightness based on sensor inputs or wireless commands. The modules are connected in series using flexible lines.
18. LED Lamp with One-Piece Snap-On Magnetic Lens Assembly
OPPLE LIGHTING ELECTRICAL APPLIANCE CO LTD, OPPLE LIGHTING ELECTRICAL APPLIANCE ZHONGSHAN CO LTD, 2016
LED lamp with an integrated lens for easy assembly, disassembly and maintenance. The lamp has a light source board with LEDs and a power module. The LEDs are covered by a one-piece lens assembly that attaches to the light source board using snap connections and magnetic attraction. This allows quick assembly and disassembly of the lens without tools. The integrated lens protects the LEDs and simplifies lamp production compared to separate lens components.
19. Modular LED Floodlight with Independently Controllable and Dimmable LED Modules
SEOUL TECH ONE INC, 2015
A modular LED floodlight design that enables independent control and dimming of each LED module for high efficiency and flexibility. The floodlight is composed of a base substrate with multiple removable module substrates attached. Each module has its own LED array and can be dimmed independently. A detection unit monitors module operation and determines dimming levels based on conditions. This allows customized brightness and efficiency for each module rather than the whole floodlight. The modular structure enables assembly flexibility and easy replacement of modules.
20. Modular LED Display Panels with Detachable Configurable Tiles and Integrated LED Modules
BRIGHTEK OPTOELECTRONIC CO LTD, BRIGHTEK OPTOELECTRONIC SHENZHEN CO LTD, 2015
Modular LED display panels with detachable tiles that can be easily connected and disconnected to form larger displays of various sizes. The modular panels have detachable LED illuminating tiles that can be assembled into different configurations. Each tile contains an LED lighting module with LED chips on a substrate mounted on a circuit board. This allows the display to be scaled up or down by connecting/disconnecting the tiles without requiring custom-sized panels.
Increasing output and reducing costs require optimizing the process for assembling LED lighting fixtures. The patents here show a variety of inventive approaches to accomplishing this goal. These methods focus on improving the integration of components, standardizing connectors, and simplifying mounting processes.
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