Two-Part LED Connector With Spring PCB Contact Compensation
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Solution Overview
Problem
Existing LED connection elements fail to ensure reliable electrical supply to the LED light source while accommodating for PCB thickness tolerances and maintaining optimal contact pressure.
Innovation Solution
A two-part connection element design separates the contact arrangement into a connection contact in the outer ring and a supply contact in the inner ring, with the supply contact being spring-loaded and pivotable to compensate for PCB thickness variations and ensure consistent contact pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-piece contact arrangement is used, then the structure is simple, but it cannot separately optimize connection contact and supply contact functions
Solution Approach 1:
The contact arrangement is divided into two separate parts: a connection contact in the outer ring and a supply contact in the inner ring. This segmentation allows each contact to be independently optimized for its specific function - the connection contact for external conductor connection and the supply contact for PCB contact field connection, resolving the contradiction between structural simplicity and functional optimization.
2Stability of the object's composition
If rigid contact contacts are used, then the structure is stable, but they cannot compensate for PCB thickness tolerances
Solution Approach 1:
The supply contact is designed with spring elements that provide elastic compliance, allowing it to dynamically adjust to variations in PCB thickness. This dynamic characteristic enables the contact to maintain reliable electrical connection despite tolerance variations, while the overall two-ring structure provides stable mechanical support.
Solution Approach 2:
The spring-loaded supply contact changes its physical state from rigid to elastic, allowing it to deform and accommodate PCB thickness variations. The spring elements enable the contact to absorb dimensional variations through elastic deformation, maintaining stable electrical connection across different PCB thicknesses.
3Reliability
If high contact pressure is applied, then electrical connection is reliable, but it may damage the PCB contact field
Solution Approach 1:
The spring elements in the supply contact provide controlled elastic deformation that maintains optimal contact pressure without exceeding damage thresholds. The spring constant can be designed to ensure sufficient electrical connection reliability while limiting maximum contact force to protect the PCB contact field from damage.
Solution Approach 2:
The spring-loaded supply contact acts as a cushioning element that absorbs excessive contact forces before they can damage the PCB contact field. The elastic spring elements preemptively protect the delicate PCB traces by deformable absorption of mechanical stress, ensuring reliable electrical connection without harmful damage.
4Adaptability or versatility
If the contact arrangement is separated into two parts, then each contact can be optimized independently, but the assembly complexity increases
Solution Approach 1:
The inner ring containing the supply contact is nested within the outer ring containing the connection contact. This nested arrangement allows both contacts to be integrated in a compact structure while maintaining independent optimization of each contact. The nested design reduces overall assembly complexity compared to completely separate components.
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 provides a reliable electrical connection by compensating for PCB thickness variations, preventing excessive contact pressure, and extending the service life of the luminaire by maintaining optimal contact quality.
Implementation Method 1
This is preferably achieved using spring elements
Implementation Method 2
The spring-loaded arrangement of the inner ring within the outer ring allows for the compensation of unavoidable tolerances in the printed circuit board thickness
Implementation Method 3
The connecting contact therefore forms a contact surface, the supply contact forms a counter-contact surface, and the contact surface and the counter-contact surface are directly adjacent to each other
Data Source
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AI summary
Connection element for the electrical connection of an LED light source, - wherein the LED light source has a printed circuit board which is provided with contact fields for the electrical supply of the LED, - with a substantially ring-shaped frame which is intended to cover the printed circuit board and to mechanically hold it on an arrangement surface of a counter bearing, - with an outer ring and an inner ring arranged in the outer ring which together form the frame, - with a contact arrangement which is mounted in the frame and which serves for the electrical supply of the LED, - a connection contact in the outer ring for the connection of a connecting conductor, in particular without soldering, as the first part of the contact arrangement, - a supply contact in the inner ring for the electrical contacting of a contact field of the printed circuit board as the second part of the contact arrangement, wherein - the connection contact and the supply contact are connected to each other.