Card Type Light Source Alignment Groove Connector
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Solution Overview
Problem
The existing light source units with card type light sources face issues of half-fitting states between the card type light source and the power supply connector, leading to assembly failures, reduced reliability, and compromised light distribution characteristics due to insufficient electrical contact and interference with the base portion, which complicates size reduction and mounting operations.
Innovation Solution
Incorporating an alignment portion, such as an alignment groove on the card type light source or alignment holes on the power supply connector, to ensure correct fitting by confirming the alignment state visually or tactilely, preventing half-fitting states and enhancing the reliability of the light source unit while allowing for compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a card edge connector is formed on the card substrate to eliminate separate connector mounting, then working operations are reduced and size is reduced, but the power supply connector body protrudes on both front and back surfaces causing interference with the base portion
Solution Approach 1:
The power supply connector body is positioned to extend in the thickness direction of the card substrate, utilizing the Z-dimension (vertical dimension) rather than extending in the planar dimensions. This allows the connector to pass through the card substrate thickness without interfering with the base portion's main surface, solving the protrusion interference problem while maintaining the integrated card edge connector design.
2Shape
If the power supply connector body extends in the thickness direction of the card substrate, then interference with the base portion is avoided, but positioning accuracy may deteriorate
Solution Approach 1:
An alignment mark is introduced as an intermediary visual indicator to assist in accurately positioning the card type light source relative to the power supply connector during assembly. The alignment mark, formed as a light-transmissive portion on the card substrate, provides a clear visual reference that compensates for the lack of physical positioning features, ensuring accurate positioning despite the connector's vertical extension.
3Device complexity
If no alignment feature is provided, then the structure is simpler, but half-fitting states occur leading to assembly failures and reduced reliability
Solution Approach 1:
The alignment mark utilizes optical property changes (light transmissivity) to provide visual feedback during assembly. The light-transmissive portion of the card substrate creates a visible alignment indicator that changes appearance based on its position, allowing workers to easily identify correct positioning and avoid half-fitting states, thereby improving assembly reliability without significantly increasing structural complexity.
Data Source
AI summary
A light source unit includes a card type light source including a card substrate on which a light source is mounted, and a power supply connector configured to supply power to the light source. A card edge connector is formed on a part of the card substrate. The power supply connector is configured to be fitted to the card type light source via the card edge connector. The card type light source is provided with an alignment groove for confirming an alignment state with respect to the power supply connector.