LED Electrical Connector with Elastic Clamping for Automated Assembly
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Solution Overview
Problem
The existing methods for connecting an LED light's electrode to a driver board, which involve manual welding of wires, are complex, inefficient, and hinder automated production due to the difficulty in positioning and arranging wires.
Innovation Solution
An electrical connector with a conductive connection board, conductive pins, and elastic clamping portions formed by electrical connection sheets, allowing for automatic assembly without manual welding, using a bendable fastening mechanism to secure the insert terminal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual welding of wires is used to connect electrode to driver board, then electrical connection is achieved, but production process becomes complicated and inefficient
Solution Approach 1:
The patent replaces the manual welding process with a mechanical insertion system. The insert terminal is simply inserted into the elastic clamping portion formed by the connection sheets, eliminating the need for welding equipment and manual welding operations. This mechanical substitution dramatically improves production efficiency while maintaining reliable electrical connection through the elastic clamping force.
2Reliability
If manual welding of wires is used, then electrical connection is achieved, but production process becomes complex
Solution Approach 1:
The patent extracts the wire threading and welding operations from the connection process. Instead of using separate wires that need to be manually threaded through electrode pins and welded to the driver board, the invention integrates the electrical connection function into a single insert terminal that connects directly to the elastic clamping portion, simplifying the overall production process.
Solution Approach 2:
The elastic clamping portion formed by the connection sheets acts as an intermediary between the insert terminal and the electrode connection board. This intermediary structure provides both mechanical support and electrical connection in one component, eliminating the need for separate wires and welding operations.
3Reliability
If wires are manually threaded and welded, then electrical connection is achieved, but automated production becomes difficult
Solution Approach 1:
The patent replaces the complex manual welding process with a simple mechanical insertion operation. The insert terminal is designed to be inserted into the elastic clamping portion, which automatically secures the connection through elastic force. This mechanical substitution enables automated production as the insertion process can be easily automated without requiring welding equipment or skilled operators.
4Reliability
If wires are used for connection, then electrical connection is achieved, but positioning and arrangement becomes difficult
Solution Approach 1:
The patent removes the wires from the connection system and replaces them with a rigid insert terminal that has fixed positioning features. The insert terminal is designed with specific dimensions and insertion direction, making positioning and arrangement straightforward during assembly, unlike flexible wires that require manual threading and positioning.
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
Enables a simple structure for easy automatic assembly and secure electrical connections between the light source and driver boards, reducing production complexity and increasing efficiency.
Implementation Method 1
the electrical connection sheets may be bent to cause the abutting portions to be close to each other to form the elastic clamping portion
Implementation Method 2
The electrical connector is fixed on and electrically connected with the light source board via the conductive pins
Data Source
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AI summary
An electrical connector for use in implementing an electrical connection between a light source board and a driver board of an LED light, comprising a connecting board (10), where electrically-conductive pins (11) are connected onto the connecting board (10), and the electrical connector is fixed onto the light source board and electrically connected to the light source board via the electrically-conductive pins (11), also comprising two electrical connecting pieces (12), where each electrical connecting piece (12) comprises a connecting part (121) and an abutting part (122) that are integrally provided, one extremity of the connecting part (121) is fixed onto the connecting board (10), and the abutting parts (122) of the electrical connecting pieces (12) are in proximity to each other to form a flexible clamping part (123), also comprising a bendable fastening mechanism (13), where the fastening mechanism (13), when bent, is abutted against the other extremity of the connecting parts (121) so as to fix the connecting parts (121) onto the connecting board (10). The electrical connector has the advantage of being structurally simple and convenient for automated assembly.