Joint Support Strain Relief for LED Strip Light Connections
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Solution Overview
Problem
Existing LED strip light connections to power cords are fragile and prone to failure, especially in field installations where environmental conditions can compromise solder joints, and there is a lack of effective mechanical support for the entire joint.
Innovation Solution
A joint support and strain relief system comprising a cuff portion to encircle the power cord and a spade portion to secure the strip light, made of nonconductive material, which provides mechanical support and alignment, and can be attached to a substrate, with features like setbacks and tabs for easier access and securement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solder joints are used to connect power cord to strip light, then electrical connection is achieved, but mechanical strength and reliability are insufficient
Solution Approach 1:
The patent combines electrical connection and mechanical support functions into a single integrated component. The spade connector with integrated strain relief merges the electrical terminal and mechanical support structure, eliminating the need for separate solder joints and providing both electrical connectivity and mechanical strength through a unified design.
Solution Approach 2:
The spade connector acts as an intermediary component between the power cord and strip light. It provides a robust mechanical and electrical interface that eliminates direct solder joints, using the spade's structure to transfer both electrical current and mechanical load between the connected elements.
2Ease of operation
If soldering is performed in field conditions, then power connection can be made, but connection quality deteriorates due to environmental factors
Solution Approach 1:
The invention segments the connection process into distinct functional components: the spade connector provides the electrical interface, the cuff provides strain relief, and the integrated structure provides alignment guides. This segmentation allows for simpler field assembly without requiring precise soldering skills, as components can be connected through more forgiving mechanical interfaces.
Solution Approach 2:
The spade connector with integrated strain relief and alignment features is designed to be self-aligning and self-supporting during installation. The structural features automatically guide proper positioning and provide inherent support, eliminating the need for complex alignment procedures or specialized tools that would be difficult to use in field conditions.
3Strength
If traditional strain relief is used, then cable bending is prevented, but it cannot provide support for flexible cord to flexible PCB connection
Solution Approach 1:
The spade connector with integrated strain relief is designed to be universally applicable to both rigid and flexible substrates. The cuff portion provides strain relief for the power cord, while the spade portion can be mounted on either rigid housings or flexible PCBs, making the solution adaptable to various application scenarios beyond traditional rigid-to-flexible connections.
Data Source
AI summary
A joint support and strain relief that provides support for the entire joint between a power cord and a strip light is disclosed. The joint support and strain relief is comprised of a cuff portion that defines a curved interior channel designed to cradle a power cord and a contiguous spade portion in the form of a thin, flat, generally rectangular plate. The strip light is typically secured to the spade portion with adhesive. The spade portion may have sidewalls to assist with the alignment of the strip light, and those sidewalls may have attached to their upper edges horizontally inwardly-extending tabs parallel to and above the bottom of the spade portion. The joint support and strain relief may also have tabs with holes or openings that allow the piece to be attached to a substrate.