Surface Mounted LED Device PCB Gap Design
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Solution Overview
Problem
The existing surface mounted LED devices require multiple conductive wires for series connections, making it challenging to manufacture large LED string lights due to wire management and alignment issues, particularly with the need to prevent parallel connections between signal input and output ports.
Innovation Solution
A surface mounted LED device design featuring a printed circuit board (PCB) with a gap between the signal input and output conductive pads, allowing for easy severance of the signal connection using a cutting apparatus, enabling efficient series connection of LED devices without the need for multiple wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple conductive wires are used to connect adjacent surface mounted LED devices in series, then proper signal transmission and power supply can be achieved, but the number of wires increases with the number of LED devices, making wire preparation and alignment difficult
Solution Approach 1:
The patent merges the functions of multiple separate conductive wires (power wire, ground wire, and signal wire) into a single integrated conductive wire. The PCB gap design allows this single wire to pass through and establish all necessary electrical connections (power, ground, and signal) between adjacent LED devices simultaneously, eliminating the need for multiple separate wires and their complex alignment
Solution Approach 2:
The PCB is segmented by introducing a gap between the signal input conductive pad and signal output conductive pad. This segmentation allows the conductive wire to be cleanly divided at the gap location, ensuring that the signal wire is properly severed between adjacent LED devices while maintaining power and ground connections, thus simplifying wire management in series configurations
2Reliability
If surface mounted LED devices are connected in series with multiple wires, then proper electrical connections can be established, but aligning multiple wires to multiple ports becomes an additional manufacturing challenge
Solution Approach 1:
The invention combines multiple electrical connection functions (power supply, ground connection, and signal transmission) into a single conductive wire that passes through the PCB gap. This merging reduces the manufacturing complexity from aligning multiple wires to multiple ports to simply routing one wire through the gap, significantly easing the alignment process while maintaining all necessary electrical connections
Solution Approach 2:
The PCB gap acts as an intermediary structure that facilitates the connection process. By providing a defined gap location, it serves as a mediator that guides the conductive wire through the appropriate path, ensuring proper alignment and connection without requiring complex manual alignment procedures for multiple wires and ports
Data Source
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AI summary
A surface mounted Light Emitting Diode (LED) device includes a printed circuit board (PCB) (1), at least one color LED chip (21) mounted on the PCB, and a driving chip (20). The driving chip (20) is mounted on the PCB and electrically connected to the at least one color LED chip (21) to drive the at least one color LED chip (21). The driving chip (20) has a signal input port electrically connected to a signal input conductive pad (6), and a signal output port electrically connected to a signal output conductive pad (7). A gap (8) is located between the signal input conductive pad (6) and the signal output conductive pad (7) for creating a space for a cutting apparatus to sever any conductive line through the gap (8), and making a manufacturing procedure of the surface mounted LED device easier.