LED Electrical Connector with Bendable Conductive Members
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Solution Overview
Problem
The manufacturing of light-emitting diode (LED) lighting fixtures is time-consuming and costly due to the use of solder, and existing designs with top-mounted electrical contacts pose challenges for conventional mounting and heat dissipation.
Innovation Solution
The development of novel electrical connectors that attach to the top-mounted electrical contacts of light-emitting device packages, allowing for easy connection to circuit boards and reducing light degradation by positioning the connectors to minimize obstruction of emitted light, while also enabling efficient heat management through bendable conductive members that can be aligned to reduce interference during the attachment process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solder is used in the manufacturing process of LED lighting fixtures, then reliable electrical connections are achieved, but manufacturing time increases and costs rise
Solution Approach 1:
The electrical connection system is divided into separate modular components: a connector assembly with conductive members that attaches to the LED package, and a separate socket or receptacle on the circuit board. This segmentation eliminates the need for soldering while maintaining reliable electrical connections through mechanical engagement, thereby improving manufacturing efficiency without sacrificing connection reliability.
2Adaptability or versatility
If top-mounted electrical contacts are used on LED packages, then flexibility in package design is improved, but conventional mounting and heat dissipation become problematic
Solution Approach 1:
The connector assembly extends vertically from the top-mounted electrical contacts, utilizing the vertical dimension to provide both electrical connection and mechanical mounting functions. The conductive members extend downward to engage with sockets on the circuit board, while the connector housing provides a mounting interface. This dimensional approach resolves the conflict between top-mounted contact flexibility and conventional mounting requirements.
Solution Approach 2:
The connector assembly serves multiple functions simultaneously: it provides electrical connection through conductive members, mechanical mounting through the connector housing, and heat dissipation pathways through thermally conductive materials. This multi-functionality resolves the contradiction by making the same structure serve both electrical and thermal management purposes.
3Ease of operation
If electrical connectors are positioned to connect to top-mounted contacts, then connection to circuit boards is simplified, but light output may be degraded due to obstruction
Solution Approach 1:
The connector housing and conductive members are strategically positioned and shaped to minimize interference with the light emission path. The design incorporates light-transmitting or light-reflecting surfaces in areas where light passes, while maintaining electrical connection functionality. This localized optimization allows simple connection geometry without significant light output degradation.
Data Source
AI summary
Electrical connectors for attachment to electrical contacts of light emitting devices as well as light emitting device packages and lamp assemblies that use such connectors are provided. Further, methods for assembling light emitting device packages that use such connectors are provided. The electrical connector, for example, can have a plug housing with an electrically conductive socket engaging connection for engaging a socket. The electrical connector can also have an electrically conductive member extending from the plug housing and connected to the socket engaging connection. The electrically conductive member can have an end distal from the plug housing that forms a contact base configured to attach to an electrical contact on a light emitting device.