C-Shaped Connector for LED Lighting Thermal Management
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Solution Overview
Problem
Existing connectors for LED lighting devices, especially those with Ingress Protection IP protection, are bulky and often create a 'step' when mounted at end edges, hindering thermal coupling with heatsinks and restricting mounting flexibility, especially when corners are involved.
Innovation Solution
A C-shaped or U-shaped connector that can be positioned along the length of the lighting device, providing electrical contact through resilient sliding contacts or piercing pins, allowing full surface contact and mechanical fixation without creating gaps, and is designed to work with both rigid and flexible LED modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a connector is mounted at the end edge of the lighting device, then electrical contact with the conductive lines is achieved, but a step or gap is formed between the lighting device and the heatsink surface, hindering thermal coupling
Solution Approach 1:
The connector is repositioned from the end edge to the upper surface of the lighting device, changing the spatial dimension of connection. This allows the connector to engage with contact formations on the upper surface rather than at the extremity, eliminating the step formation while maintaining electrical contact functionality.
Solution Approach 2:
The lighting device is designed with multiple contact formations distributed along its length on the upper surface, allowing the connector to make contact at an intermediate position rather than requiring end-edge mounting. This segmentation of contact points enables flexible positioning.
2Strength
If a bulky connector is used to ensure tensile strength and safety, then mechanical strength is improved, but the connector creates a step that restricts mounting flexibility and thermal contact
Solution Approach 1:
By moving the connector from end-edge mounting to upper surface mounting, the spatial configuration changes, allowing the connector to engage horizontally rather than vertically at the extremity. This eliminates the step formation while maintaining the connector's structural integrity and tensile strength capabilities.
Solution Approach 2:
The connector design accommodates both IP-protected and non-IP lighting devices through a universal mounting approach on the upper surface, rather than requiring different connector types for different mounting scenarios. This enhances adaptability across different device types.
3Reliability
If the connector is positioned at an end position, then electrical connection is established, but mounting at corner positions between converging walls becomes problematic due to edge location within dihedral angle
Solution Approach 1:
The connector is repositioned from end-edge locations to the upper surface of the lighting device. This dimensional change allows the connector to be positioned away from geometric constraints such as corner positions and dihedral angles, enabling easier installation in various mounting configurations including corner mounting scenarios.
Solution Approach 2:
Contact formations are distributed at different locations along the lighting device, including positions on the upper surface that are accessible for connector engagement. This local distribution of contact points provides flexibility in positioning the connector away from problematic edge positions.
4Temperature
If a cavity or groove is created in the heatsink to accommodate the connector, then thermal contact is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The connector and lighting device are repositioned so that the connector engages with the upper surface rather than protruding from the end edge. This eliminates the need for cavities or grooves in the heatsink, allowing for full surface contact between the lighting device and heatsink, thereby simplifying heatsink manufacturing while maintaining optimal thermal coupling.
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
Enables flexible electrical and mechanical connections, optimized thermal dissipation, and compliance with safety regulations by eliminating steps and gaps, ensuring reliable contact throughout the device's lifetime.
Implementation Method 1
providing electrical contact through resilient sliding contacts or piercing pins
Implementation Method 2
optimized thermal dissipation, and compliance with safety regulations by eliminating steps and gaps, ensuring reliable contact throughout the device's lifetime
Data Source
Figure 1~2
Figure 3~5
AI summary
A connector for lighting devices (D) including an elongate planar support member (10) having a front surface with electrically conductive lines (12) and at least one electrically powered light radiation source (L) thereon. Connector (100) includes a C-shaped body (102) having a web portion (102a) and two side portions (102b). Said C-shaped body (102) is locatable astride planar support member (10) with web portion (102a) facing said front surface, and electrical contact means (104, 104') extending from web portion (102a) between side portions (102b) for contacting electrically conductive lines (12) on the front surface of planar support member (10).