Isolated Solder Pad LED Strip Bussing System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional LED strip bussing systems require significant time, labor, and materials due to the need for insulation between copper solder pads to prevent short circuits, and demand experienced personnel for fabrication.
Innovation Solution
The solution eliminates the need for insulation between copper solder pads by using isolated solder pads, allowing for direct soldering of power input leads without risk of short circuits, thereby simplifying the bussing process and reducing material and labor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation material is used between copper solder pads to prevent short circuits, then safety is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The solder pads are segmented and isolated from each other by spacing them apart on the PCB, eliminating the need for insulation material between adjacent pads. This segmentation approach maintains safety while reducing complexity.
Solution Approach 2:
The insulation material is completely removed from the design. Instead of using insulation between pads, the design relies on the PCB layout and spacing to prevent short circuits, extracting the harmful element (insulation material) while maintaining the protective function.
2Reliability
If insulation material is used between copper solder pads, then short circuit prevention is improved, but manufacturing time and labor cost increase
Solution Approach 1:
By segmenting the solder pads and spacing them appropriately on the PCB, the design eliminates the need for additional insulation installation steps, significantly reducing fabrication time while maintaining short circuit prevention.
Solution Approach 2:
The PCB layout itself provides the protection against short circuits through proper pad spacing and routing design, making the system self-protecting without requiring additional insulation materials or installation steps.
3Manufacturing precision
If experienced personnel are used for conventional LED strip fabrication, then manufacturing precision is improved, but labor cost increases
Solution Approach 1:
The PCB-based design segments the electrical connections into predefined, isolated solder pads that guide the assembly process, reducing the need for complex manual wiring and lowering the skill level required for fabrication.
Solution Approach 2:
The PCB layout with isolated pads and pre-defined connection points makes the assembly process self-guiding, allowing less experienced personnel to achieve precise connections without requiring extensive training or expertise.
4Reliability
If conventional bussing method is used with insulation material, then safety is improved, but material cost increases
Solution Approach 1:
The insulation material is completely extracted from the design. The PCB layout with spaced solder pads provides inherent protection against short circuits without requiring any additional insulation materials, thereby eliminating material cost.
Solution Approach 2:
The design uses the PCB itself as the protective structure through its layout and spacing, replacing expensive insulation materials with a cost-effective printed circuit board design that provides the same protective function.
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
This approach reduces the time and cost of manufacturing LED strips, lowers the technical skill required, and enhances safety by minimizing the likelihood of short circuits, while allowing for easier segmentation and connection of LED strips.
Implementation Method 1
copper solder pads... direct soldering of power input leads... electrical connection
Data Source
AI summary
Bussing systems for bussing strips of LEDs that do not require insulation between adjacent copper solder pads, that enable cutting of each of the LED strips without loss of functionality for the cut strips(s), and that permit a power input lead to be soldered onto each strip without incident.