LED Light Connector Header for Reliable Circuit Board Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge in manufacturing LED-based lights is the difficulty in making reliable electrical connections between flexible wires and electrical assemblies due to wire flexibility and memory effects, which complicates positioning and spacing during assembly, especially in automated processes.
Innovation Solution
The use of connector headers, such as pin connector headers and circuit connector headers, which are designed to securely and predictably connect the power supply circuit board to the LED circuit board and the fixture, ensuring consistent electrical connections through rigid leads and secure engagement mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flexible wires are used to make electrical connections between electrical assemblies, then the wires can be easily manipulated and routed, but the wires are difficult to grasp and position, and memory effects cause inconsistencies in curvature and spacing
Solution Approach 1:
The patent changes the physical state of the connecting element from flexible wire to rigid rod with controlled flexibility. The connector header uses rigid leads that maintain consistent curvature and spacing, eliminating the positioning difficulties of flexible wires while preserving the ability to route connections. This parameter change transforms the connecting element's mechanical properties to resolve the contradiction between flexibility and controllability.
Solution Approach 2:
The patent introduces a connector header as an intermediary component between electrical assemblies. This mediator component provides a structured interface that holds connecting leads in predetermined positions, making it easier to grasp and position during assembly. The connector header acts as a bridge that translates the need for flexible connections into a rigid, controllable structure.
2Ease of operation
If manual assembly processes are used with flexible wires, then some flexibility in assembly is maintained, but the process becomes time-consuming and less reliable due to difficulty in maintaining desired orientation and spacing
Solution Approach 1:
The connector header is pre-configured with connecting leads in their desired orientation and spacing before assembly. This preliminary action eliminates the need for time-consuming positioning and alignment during the assembly process. The predetermined positions of the leads ensure consistent curvature and spacing, making the assembly process faster and more reliable while maintaining flexibility in the overall assembly procedure.
3Manufacturing precision
If rigid leads are used in connector headers, then consistent curvature and spacing are achieved, but the leads may be harder to manipulate during assembly
Solution Approach 1:
The connector header is divided into distinct segments: a body portion that provides structural support and predetermined positioning, and connecting leads that extend from the body. This segmentation allows the rigid body to ensure consistent curvature and spacing while the leads can be manipulated independently during assembly. The modular structure resolves the contradiction by separating the functions of precision positioning and ease of manipulation into different components.
Data Source
AI summary
An LED-based light configured for replacing a conventional fluorescent light in a fluorescent light fixture comprises: an LED circuit board including at least one LED; a power supply circuit board configured to supply power to the at least one LED; an end cap carrying at least one pin configured for connection to the fixture; a pin connector header including a first body retentively supporting at least one pin connecting lead and configured to engage the power supply circuit board such that the pin connecting lead is positioned to electrically connect the power supply circuit board and the pin; and a circuit connector header including a second body retentively supporting at least one circuit connecting lead and configured to engage the power supply circuit board such that the circuit connecting lead is positioned to electrically connect the power supply circuit board and the LED circuit board.