LED PCB Feed Connector Layout for Cut-to-Fit Terminal Placement

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Solution Overview

Problem

The challenge of properly positioning wire terminal blocks on cut-to-fit LED PCBs within architectural fixtures is complicated by the random placement of terminal blocks after cutting from longer stock, necessitating labor-intensive manual soldering and difficult quality control.

Innovation Solution

The solution involves freely-placed terminal blocks that can be adhered or fastened at various positions across the LED PCB, eliminating the need for soldering and allowing 'push-in' connections, with features like adhesive, mechanical fasteners, and alignment tools to ensure proper positioning and electrical contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If terminal blocks are permanently mounted to the PCB before fixture assembly, then electrical connection reliability is improved, but positioning flexibility and quality control difficulty worsen due to random placement after cutting

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidpositioning flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The terminal block assembly is divided into separate components: the PCB with conductor portions, the housing with conductor contacts, and wire terminals. These segments can be assembled in different sequences and configurations, allowing the terminal block to be positioned at various locations on the PCB after cutting while maintaining reliable electrical connections.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system transitions from a static, pre-mounted terminal block configuration to a dynamic assembly process where the housing and wire terminals can be positioned and attached at various locations on the PCB after cutting, providing adaptability while ensuring reliable electrical connections through the conductor-conductor contact interface.

Inventive Principle:

Principle #15Dynamics

2Reliability

If manual soldering is used to attach terminal blocks, then electrical connection reliability is improved, but labor intensity and manufacturing complexity worsen

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The soldering process is replaced with a mechanical attachment system. The housing contains conductor contacts that mechanically engage with exposed conductor portions on the PCB, and wire terminals are mechanically attached to the housing. This eliminates the need for soldering while maintaining reliable electrical connections and simplifying the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If terminal blocks are pre-positioned on LED PCBs, then electrical connection consistency is improved, but wire routing flexibility worsens due to fixed positions

Engineering Contradiction:

Improveelectrical connection consistencyVSAvoidwire routing flexibility

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The system allows dynamic positioning of the housing and wire terminals at various locations on the PCB after cutting. The conductor contacts in the housing can engage with exposed conductor portions at different positions, enabling flexible wire routing while maintaining consistent electrical connections through the mechanical contact interface.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The terminal block is segmented into the housing with conductor contacts and the wire terminals. This segmentation allows the housing to be positioned at various locations on the PCB to accommodate different wire routing requirements, while the conductor contacts ensure consistent electrical connections regardless of position.

Inventive Principle:

Principle #1Segmentation

4Reliability

If soldering is required for wire connections, then electrical connection reliability is improved, but installation time and labor cost worsen

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidinstallation speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The soldering process is completely replaced with a mechanical push-in connection system. Wire terminals are inserted into the housing and secured through mechanical engagement with conductor contacts, eliminating the need for soldering tools and skills. This maintains reliable electrical connections while dramatically reducing installation time and labor costs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12580330B2Electrical feed connector system and method for light emitting diode (LED) circuit boards with varied placement of wire terminal connection points

Publication Date: 2026.03.17 UPSIDE FOODS INC

AI summary

A system comprises a printed circuit board (PCB) substrate and a housing. The PCB substrate has a plurality of light emitting diodes (LEDs), a first plurality of electrical conductor portions and a second plurality of electrical conductor portions. The housing has a first side and a second side opposite the first side. The housing has on the first side a first wire terminal and a second wire terminal. The housing has on the second side a first conductor contact and a second conductor contact. The housing is configured to be attachable to the PCB substrate so that first conductor contact is electrically coupled to an electrical conductor portion from the first plurality of electrical conductor portions and the second conductor contact is electrically coupled to an electrical conductor portion from the second plurality of electrical conductor portions.