Hermaphroditic LED Connector Series Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing lighting systems face challenges in efficiently connecting LED boards of varying lengths due to high inventory and manufacturing costs associated with different lengths and types of connectors, which increases the overall system cost.
Innovation Solution
The implementation of hermaphroditic mating interfaces on electrical connectors mounted to the LED boards, allowing for easy and efficient connection of LED assemblies in series by plugging male mating ends into female mating ends, reducing the need for multiple connector types and simplifying the power transfer between boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different length LED boards are provided to meet different application requirements, then the lighting system can be adapted to various applications, but the inventory cost and manufacturing complexity increase significantly
Solution Approach 1:
The LED board is designed with universal connectors at both ends that can connect to identical connectors on adjacent LED boards. This allows LED boards of the same standard length to be ganged together in series to create lighting systems of various total lengths, eliminating the need to manufacture and maintain multiple inventory types of different lengths.
2Adaptability or versatility
If smaller LED boards are ganged together to achieve different lengths, then the lighting system can be flexible in configuration, but the cost of supplying power to each LED board increases
Solution Approach 1:
Multiple LED boards are electrically connected in series through the hermaphroditic connectors, merging them into a single continuous electrical circuit. Power is supplied to the first LED board, which then passes electrical current through the connected boards in series, eliminating the need for separate power supplies at each board location.
3Adaptability or versatility
If different types of connectors are used for different LED board configurations, then specific connection requirements can be met, but the design and manufacturing cost of various connector types increases
Solution Approach 1:
A single universal connector design with hermaphroditic mating interfaces is used at both ends of each LED board. This identical connector type can connect any LED board to any other LED board of the same model, eliminating the need to design and manufacture multiple different connector types for different configurations.
Solution Approach 2:
The connector integrates both male and female mating interfaces in a single housing, combining what would traditionally require two different connector types into one universal component. This reduces connector variety and simplifies the bill of materials.
4Ease of manufacture
If LED boards are connected in series to reduce inventory, then the system cost decreases, but the reliability of electrical connection between boards may be compromised
Solution Approach 1:
The connector housing integrates multiple contact channels with corresponding plug and receptacle contacts within a single unified structure. This ensures all electrical connections are made simultaneously within one mating action, reducing the risk of misalignment or incomplete connections that could compromise reliability.
Solution Approach 2:
The connector housing serves as a protective intermediary that shields and aligns the delicate plug and receptacle contacts during mating. This protective structure ensures reliable electrical connection by maintaining proper alignment and protecting contacts from damage.
Data Source
AI summary
An LED assembly includes electrical connectors mounted to an LED board each having a connector housing having contact channels holding plug contacts and receptacle contacts arranged in the connector housing to form a hermaphroditic mating interface. The plug contacts have male mating ends configured to be plugged into female mating ends of receptacle contacts of a mating LED assembly. The receptacle contacts have female mating ends configured to receive male mating ends of plug contacts of the mating LED assembly.