Jumper Connector for LED Lighting Assembly
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Solution Overview
Problem
Current lighting assemblies using LEDs face challenges in efficient heat dissipation and require complex, costly manufacturing processes for thermally conductive substrates that also provide electrical interconnection, leading to time-consuming assembly steps.
Innovation Solution
The introduction of jumper connectors that securely attach lighting components to a heat sink substrate while establishing an electrical connection between them, allowing for simultaneous heat dissipation and power transmission during the same manufacturing step, using a connector body with a conductor that engages contact pads on the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple lighting components are individually secured to the substrate and then electrically connected with wires, then electrical interconnection is achieved, but assembly time and manufacturing complexity increase
Solution Approach 1:
The patent combines the mechanical securing function and electrical interconnection function into a single integrated jumper connector. The connector body mechanically secures the lighting component to the substrate while the integrated conductor simultaneously establishes electrical connection, eliminating the need for separate wire soldering operations and reducing assembly time.
Solution Approach 2:
The jumper connector serves multiple functions simultaneously: it acts as a mechanical fastener to secure the lighting component, provides electrical connection through its conductor, and enables thermal communication with the substrate. This multi-functionality reduces the number of separate components and assembly steps required.
2Adaptability or versatility
If thermally conductive substrates are used to provide mechanical support, electrical interconnection, and heat dissipation, then all functions are integrated, but manufacturing complexity and cost increase
Solution Approach 1:
The patent divides the system into separate functional components: a simple substrate that provides mechanical support, a jumper connector that provides electrical interconnection and thermal communication, and lighting components. This segmentation allows each component to be manufactured independently using simpler, more cost-effective processes while still achieving the overall multi-functional system.
Solution Approach 2:
The jumper connector acts as an intermediary component between the substrate and the lighting component. It mediates the transmission of electrical signals and thermal energy between these two elements, allowing the substrate itself to remain simple without requiring complex multi-functional integration.
3Reliability
If wires are soldered to connect circuit boards after securing to substrate, then electrical connection is established, but the multi-step process increases manufacturing time
Solution Approach 1:
The electrical connection capability is built into the jumper connector during its manufacturing process, before assembly. The conductor is pre-positioned and integrated with the connector body, so that when the connector is installed, electrical connection is automatically established without requiring subsequent soldering or wire attachment operations.
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 solution enables rapid and cost-effective assembly of LED lighting assemblies with efficient heat dissipation and electrical interconnection, reducing manufacturing complexity and time while maintaining performance.
Implementation Method 1
a heat sink or other heat dissipating device is utilized
Implementation Method 2
the conductor is configured to be electrically connected to more than one lighting component
Data Source
AI summary
A jumper connector for connecting lighting components to one another includes a connector body having a mating surface configured to engage more than one lighting component, where the connector body is configured to be secured to a substrate by a fastener. The jumper connector also includes a conductor held by the body, wherein the conductor is configured to be electrically connected to more than one lighting component during the same manufacturing step in which the connector body is secured to the substrate.