Connector Design for LED Illumination Devices
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Solution Overview
Problem
Illumination devices using LEDs face issues with heat dissipation and accidental voltage application due to protruding connectors, which reduce commercial value and risk LED damage.
Innovation Solution
A connector design with an insulating housing and conductive contacts that do not protrude from the circuit board, ensuring insulation and preventing high voltage application, while maintaining effective heat dissipation through a metal heat transfer system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the connector receiving portion protrudes high on the LED board surface to facilitate connection, then the connector can be easily connected to the lighting device, but it blocks light from the LEDs and produces unwanted shadows
Solution Approach 1:
The connector receiving portion is repositioned from a protruding structure on the LED board surface to a recessed structure on the opposite side of the board. This dimensional change allows the connector to be connected easily while preventing it from blocking light emitted by the LEDs on the other surface.
2Temperature
If conductive materials such as aluminum are used for the radiator and LED board to enhance heat radiation properties, then heat dissipation is improved, but accidental voltage can be applied to the LEDs through these conductive paths
Solution Approach 1:
An insulating housing is introduced as an intermediary component between the conductive LED board and the connector. This housing maintains the conductive properties of the LED board for heat dissipation while preventing accidental voltage application to the LEDs through the connector path.
3Reliability
If the connector is designed with insulating properties at the end portion to prevent voltage application, then LED protection is improved, but the connector structure becomes more complex
Solution Approach 1:
The insulating housing is merged with the connector receiving portion structure, combining the insulation function with the existing connector housing. This integration provides LED protection while minimizing additional structural complexity.
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
The solution reduces shadow formation and prevents unexpected voltage application to LEDs, enhancing the illumination device's commercial value and operational safety.
Implementation Method 1
the contact is insulated from the circuit board in the joining portion
Implementation Method 2
the contact is exposed in the first portion so as to be capable of contacting the first main surface
Implementation Method 3
heat in a device is effectively dissipated to the outside through the board and the radiator
Data Source
AI summary
A connector (27) is adapted to be connected to a circuit board (23) and has an insulating housing (41) adapted to be mounted to one end portion of the circuit board. The housing is provided with conductive contacts (42) each having a shape along the housing. The housing has first and second portions (51, 52) that respectively face both surfaces of the circuit board when the housing is mounted to the circuit board, and a joining portion (54) joining the first and second portions together. The contacts are insulated from the circuit board in the joining portion and are exposed in the first portion so as to be capable of contacting the surface of the circuit board.