Solderless LED Connector with Segmented Cavity
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Solution Overview
Problem
Conventional connectors for LED modules are costly and inefficient, often requiring soldering processes that expose electrical components, leading to reduced brightness and increased costs, while lacking solderless solutions that can efficiently connect LED modules to thermal substrates and optical elements.
Innovation Solution
The development of connector devices and systems that provide solderless connections, featuring a connector body with interchangeable optical elements and a housing for electrical wires, allowing for efficient mechanical and electrical coupling of LED modules to thermal substrates and optical elements, thereby covering electrical components to prevent light interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connectors with soldering processes are used, then electrical connections can be established, but manufacturing costs increase and processing steps become complex
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical mechanical system) with a mechanical press-fit connection system. The connector uses a recessed cavity that receives the LED module's electrical contacts through direct mechanical engagement, eliminating the need for soldering equipment, flux, and heating processes while maintaining reliable electrical connection.
Solution Approach 2:
The connector body is designed as a single-use, disposable component that integrates the electrical connection function. Rather than using expensive, reusable soldering equipment and materials, the patent employs an inexpensive plastic connector body with molded-in electrical contacts that achieves reliable connection through simple insertion and press-fit mechanics.
2Reliability
If electrical components are exposed in conventional connectors, then electrical connections are established, but light brightness is reduced due to interference from electrical components
Solution Approach 1:
The connector body is segmented into distinct functional zones: a recessed cavity for electrical contact establishment and an open upper portion for light emission. This segmentation allows electrical components to be contained within the recessed area while leaving the light path clear, preventing interference between electrical components and emitted light.
Solution Approach 2:
The patent moves electrical components from the light-emitting plane to a recessed lower plane within the connector body. By creating a vertical dimension separation between the electrical contact area and the light emission area, the design allows both electrical functionality and optical performance to coexist without interference.
Data Source
AI summary
Connector devices, systems, and related methods for connecting light emitting diode (LED) modules to thermal substrates and/or optical elements are disclosed. In some aspects, a connector device can include a connector body having a first side configured to engage an LED module and a second side configured to engage an optical element for mechanically coupling the LED module to the optical element. The connector device can further include a housing configured to receive a portion of an electrical wire for electrically coupling the LED module to the electrical wire. A connector system can include an annular body defining an opening and at least one LED module disposed in a portion of the connector. The connector can be configured to cover a portion of the LED module and leave another portion of the LED module exposed or visible.