LED Connector Insert Molding with Terminal Gap and Heat Dissipation
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Solution Overview
Problem
Conventional LED units face challenges in efficiently radiating heat and preventing short-circuits due to close terminal connections, and the production process is costly and prone to assembly errors, especially when changing LED grades or shapes.
Innovation Solution
The method involves insert molding a connector with a gap between terminal parts and using a conductive metallic bus bar with a heat-radiating opening and shock-absorbing portion to manage heat and impact, ensuring efficient heat dissipation and secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If terminals are embedded close together in the housing, then device complexity is reduced, but short-circuit risk increases due to large LED contact areas
Solution Approach 1:
A positioning member (protrusion) is introduced as an intermediary element between the two terminals. This protrusion physically separates the terminals and prevents them from coming into contact with both anode and cathode simultaneously, thus eliminating the short-circuit risk while maintaining a compact connector structure.
2Ease of manufacture
If LED lamp module is produced as an integral unit, then assembly process is simplified, but production cost increases when LED grade or shape changes
Solution Approach 1:
The LED lamp module is segmented into separate components: the LED chip, the holder, and the connector. This allows the LED chip to be independently replaceable based on different specifications without requiring changes to the holder or connector, thus reducing production costs when LED grades or shapes change while maintaining simplified assembly.
3Illumination intensity
If high-intensity LED is used, then illumination intensity is improved, but heat radiation efficiency deteriorates
Solution Approach 1:
The heat-radiating function is extracted from the LED chip itself and assigned to a dedicated heat-radiating piece made of heat-conductive material. This piece is in direct contact with the LED chip's heat-generating portion and extends to the housing, creating a separate heat dissipation pathway that allows high-intensity LEDs to operate efficiently without overheating.
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 effectively prevents short-circuits by maintaining a specific distance between terminal connections and enhances heat radiation, improving the reliability and efficiency of LED units while reducing production costs and assembly complexities.
Implementation Method 1
arranging a positioning member in between the port connecting portions
Implementation Method 2
a heat-radiating opening formed on the housing with which the bus bar is integrally formed; and a heat-radiating space interposed between the non-packaging surface and the heat-radiating opening
Implementation Method 3
a heat-radiating piece folded toward the non-packaging surface is coupled to the LED packaging portion
Implementation Method 4
a shock-absorbing portion for absorbing a shock generated by connecting the electric wire is formed between the wire-connecting portion and the LED packaging portion
Data Source
AI summary
A connector includes: one terminal having a part-connecting portion to be connected to an anode of an LED; and the other terminal having the part-connecting portion to be connected to a cathode of the LED; and a housing in which the terminals are embedded. The connector is made by insert-molding. The terminals are arranged in a cavity formed between upper and lower dies so that the part-connecting portions are arranged in the same plane with a gap. An outer shape of the cavity corresponds to an outer shape of the connector. After a projection formed on the upper die is interposed between the part-connecting portions, the cavity is filled with melted synthetic resin to mold the housing.