LED Assembly Electrical Connector Structural Support
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Solution Overview
Problem
Existing LED lighting systems require a separate support substrate for physical support, which can lead to issues like light absorption, increased cost, and difficulty in secondary optics, as well as unnecessary weight.
Innovation Solution
The use of electrical connectors to provide both electrical connection and physical support between LEDs, eliminating the need for a separate substrate, and allowing for flexible three-dimensional configurations and improved heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a separate support substrate is used for physical support, then structural stability is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines the electrical connection function and mechanical support function into a single electrical connector component. The electrical connector provides both electrical connectivity between LEDs and structural support, eliminating the need for a separate support substrate and reducing overall device complexity.
Solution Approach 2:
The electrical connector is designed to perform multiple functions simultaneously: it provides electrical connection between LED components and serves as the mechanical support structure. This multi-functionality reduces the number of components needed and simplifies the overall device architecture.
2Strength
If a separate support substrate is used, then physical support is improved, but light energy absorption increases
Solution Approach 1:
The patent extracts the support function from a separate substrate and integrates it into the electrical connector. This eliminates the additional material layers that would absorb light energy, allowing more light to pass through or be emitted from the LED assembly without interference from substrate materials.
3Strength
If a separate support substrate is used, then structural support is improved, but flexibility in three-dimensional configuration is limited
Solution Approach 1:
The electrical connector is designed with flexible properties that allow the LED assembly to be configured in various three-dimensional arrangements. The connector can bend and adapt to different spatial configurations while maintaining both electrical connection and mechanical support, enabling dynamic design flexibility.
4Device complexity
If electrical connectors provide both electrical connection and physical support, then device complexity is reduced, but stress on connectors increases
Solution Approach 1:
The electrical connector is constructed from composite materials or material combinations that provide both high electrical conductivity and high mechanical strength. This allows the single component to handle both electrical connection and mechanical support loads without excessive stress, maintaining reliability while simplifying device architecture.
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 costs, enhances light efficiency by eliminating substrate absorption, and allows for more versatile and robust LED configurations without the need for additional support structures.
Implementation Method 1
An electrical connector electrically connects the plurality of LEDs
Implementation Method 2
The LEDs and or the electrical connector may be covered in an encapsulant. The electrical connector may be at least partially covered in an insulator.
Data Source
AI summary
An LED assembly comprises a string of LEDs. An electrical connector electrically connects the plurality of LEDs and provides the physical support between the LEDs. Lamps incorporating the LED assembly are provided. Methods of making the LED assembly are also provided.