Low-Profile LED Connector Assembly Through-Board Design
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Solution Overview
Problem
Existing connectors for LED circuit boards have a high profile that obstructs light emission and is not suitable for densely packed electronic devices, necessitating a reduction in connector height to accommodate smaller form factors.
Innovation Solution
A connector assembly with a housing that extends through an opening in the LED circuit board from the rear side to the front side, featuring a contact channel for electrical connection and a poke-in contact with a wire trap, allowing for a low-profile design that does not obstruct light emission while maintaining reliable electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connectors are mounted on the top side of the circuit board protruding upward, then electrical connectivity is achieved, but the height profile becomes too large and obstructs light emission from LEDs
Solution Approach 1:
The connector assembly is inverted relative to traditional designs: instead of mounting the connector body on the top side of the circuit board with contacts protruding upward, the housing body is mounted on the rear side of the board and extends through an opening to the front side. This inversion allows the electrical contacts to be positioned at the front edge of the board rather than protruding upward, eliminating light obstruction while maintaining electrical connectivity.
Solution Approach 2:
The connector assembly transitions from a vertical protrusion configuration to a horizontal through-board configuration. By routing the housing body through the circuit board from rear to front, the design moves the connector functionality to a different spatial dimension, reducing the vertical height profile while preserving electrical connection capabilities.
2Length of stationary object
If connector height is reduced for smaller electronic devices, then light emission is no longer obstructed, but maintaining reliable electrical connectivity becomes more difficult
Solution Approach 1:
The contact assembly is nested within the housing body, with the contact channel extending through the housing from the front opening to the rear. This nesting allows the electrical contacts to be positioned at the front edge of the circuit board while the contact mechanism remains protected within the housing structure, maintaining reliable connectivity with a low profile.
Solution Approach 2:
The housing body acts as an intermediary structure that extends through the circuit board, providing a protected pathway for the electrical contacts. This intermediary housing allows the contacts to reach the front edge for connectivity while the bulk of the connector structure remains recessed, achieving low profile without sacrificing reliability.
3Length of stationary object
If the connector body extends through the circuit board opening, then a low-profile design is achieved, but the complexity of the housing structure increases
Solution Approach 1:
The housing body performs multiple functions: it provides structural support, guides the contact assembly through the circuit board, protects the electrical contacts, and defines the opening geometry. This multi-functionality reduces the need for additional separate components, achieving a low-profile design without proportionally increasing overall system complexity.
Data Source
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AI summary
A connector assembly (204) includes a housing (220) having a body (224) and a head (226) extending outward from the body (224). The housing (220) is coupled to an LED circuit board with the head (226) mounted to a front side of the LED circuit board and with the body (224) extending through an opening of the LED circuit board to a rear side of the LED circuit board. The housing (220) has driver card slot (250) in the body (224) configured to receive a driver card from the rear side of the LED circuit board. The housing (220) has a contact channel (240) open to the driver card slot (250) with a contact (222) therein. The contact (222) has a mating interface (260) configured to engage and be electrically connected to the driver card. The contact (222) has a mounting leg (244) extending from the head (226) that is configured to be mounted to the front side of the LED circuit board.