LED Light Bar Connector Nesting in PCB Groove
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Solution Overview
Problem
The traditional connector design for LED light bars in LCD devices requires cutting of the Light Guide Plate (LGP) to avoid interference, increasing processing costs and potentially causing damage when the LGP expands, which is detrimental to the design of narrow frames.
Innovation Solution
A connector design with weld legs and stitches arranged higher than the shell's bottom surface, allowing the connector to be inserted into a corresponding installing groove on the PCB, reducing protrusion height and ensuring a safe distance to prevent LGP expansion damage, while facilitating connection and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connector is arranged on the same surface as the LED with a height of 2mm, then the connector can be directly welded on the PCB through weld legs, but the LGP must be cut to avoid the protruding connector, increasing processing steps and cost
Solution Approach 1:
The connector is nested into an installing groove on the PCB, with the shell positioned below the LED surface. The weld legs extend upward from the groove to contact the PCB for welding, while the stitches provide additional connection points. This nesting arrangement allows the LGP to be arranged without cutting, as the connector does not protrude above the LED surface level.
Solution Approach 2:
The connector structure transitions from a surface-mounted arrangement to a multi-level three-dimensional configuration. The shell is positioned at a lower level (below LED surface), while weld legs and stitches extend upward to establish electrical connections with the PCB. This vertical dimensionality change resolves the conflict between connector accessibility and LGP placement.
2Reliability
If a sufficient distance is remained between the LGP and connector to prevent damage from thermal expansion, then the connector is protected, but the design of narrow frame is disadvantaged
Solution Approach 1:
The connector is nested into the installing groove on the PCB, positioning the shell below the LED surface level. This arrangement allows the LGP to be placed adjacent to the connector without requiring excessive clearance, as the protruding portion of the connector is minimized. The weld legs and stitches extend upward from the groove to maintain electrical connectivity while occupying minimal horizontal space.
Solution Approach 2:
By utilizing the vertical dimension through the installing groove, the connector occupies less horizontal space on the PCB surface. This enables tighter packaging and narrower frame design while maintaining sufficient thermal clearance between the LGP and the connector shell.
3Device complexity
If the connector shell height is reduced to match the LED height, then the LGP can be arranged without cutting, but the connector may not provide sufficient connection height for welding
Solution Approach 1:
The connector is segmented into distinct functional components: the shell (positioned below LED surface to avoid LGP interference), weld legs (extending upward for PCB welding), and stitches (additional connection elements). This segmentation allows each component to serve its specific function optimally - the shell provides structural support and positioning, while the weld legs and stitches provide electrical connectivity without requiring the entire connector to protrude above the LED surface.
Solution Approach 2:
The connector utilizes vertical space through the installing groove arrangement. The shell is positioned at a lower level below the LED surface, while weld legs and stitches extend upward to establish connections with the PCB. This multi-level vertical arrangement enables the LGP to be placed without cutting while maintaining sufficient connection height for reliable welding through the extended weld legs.
Data Source
AI summary
The present invention discloses a connector, PCB for LED Light Bar and LED Light Bar. The connector comprises the weld legs and stitches fixed to the shell of the connector, and the weld legs are arranged on the side of the connector and are higher than the bottom surface. A PCB for LED light bar is provided with the installing groove for installing the connector. Because the present invention arranges the weld legs of the connector on positions which are higher than the bottom surface of the shell and arranges the installing groove corresponding to the bottom shape of the connector on the PCB, the bottom of the connector can be arranged in the installing groove, thus the protrusion height of the connector in the LED light bar is reduced. The LGP is not cut again when installing the LGP, thereby reducing the processing step. In addition, the depth that the connector sinks into the installing groove is rationally designed, so that the sufficient safe distance is remained when the LGP is heated and expended, thereby avoiding the LGP bumping into and damaging the connector.