LED Strip Notch Design for Series Wire Cutting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing manufacturing techniques for LED strips face difficulties in converting parallel connections of LED components to series connections for color-changing functionality, particularly due to the challenge of cutting signal wires between components, which leads to soldering issues and production inefficiencies.
Innovation Solution
The introduction of recessed notches on the insulated main body of LED components allows for precise cutting of wires during the manufacturing process, enabling direct SMT soldering and efficient series signal connection without compromising the packaging of LED chips and control units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If signal wires are cut after production to convert parallel connection to series connection, then color-changing functionality is achieved, but soldering quality deteriorates due to wire tension and uneven surfaces
Solution Approach 1:
The patent applies preliminary action by pre-forming notches on the insulated main body before production. These notches are prepared in advance to guide wire cutting operations, ensuring that when wires are cut later for series connection, they do so at precise locations with proper support, maintaining soldering quality while enabling color-changing functionality.
Solution Approach 2:
The notch structure serves as an intermediary element between the insulated main body and the signal wire. It provides a dedicated cutting location that supports the wire during cutting, acting as a mediator that prevents wire deformation and ensures high-quality soldering joints while still allowing the wire to be cut for series connection.
2Adaptability or versatility
If signal wires are cut before production to form segments, then series connection is achieved, but manufacturing complexity increases significantly
Solution Approach 1:
The notch is pre-formed on the insulated main body before LED components are assembled and soldered. This preliminary preparation allows for straightforward wire cutting at the notch location during or after assembly, avoiding the complexity of pre-cutting wire segments and simplifying the overall manufacturing process while maintaining series connection capability.
3Productivity
If continuous wires are used for all LED components, then production efficiency is improved, but signal transmission in series becomes difficult
Solution Approach 1:
The notches are pre-formed on all insulated main bodies before assembly. During production, continuous wires can be efficiently soldered across all components. After assembly, the wires are simply cut at the pre-formed notch locations to enable series signal transmission, thus maintaining high production efficiency while achieving the required series connection functionality.
Solution Approach 2:
The notch acts as an intermediary structure that facilitates the transition from continuous wire configuration to segmented wire configuration. It provides a standardized cutting location that enables easy conversion from parallel to series connection after efficient production with continuous wires, resolving the contradiction between production efficiency and series signal transmission capability.
Data Source
AI summary
An LED strip includes a plurality of LED components and a wire set, the LED component comprising: an insulated main body, conductive terminals fixed on the insulated main body and connected to the wire set, and lighting an LED chip and a control unit configured on the insulated main body. The insulated main body has recessed notches. The wire set at least includes a first wire running through the notch, and the first wire is formed with a cut portion. When producing the LED strip in series connection, the LED components and the corresponding continuous wire can be soldered together directly by the means of SMT technique. Then, using a cutter and the preset notch, the wire can be cut at the position of the notch. In this way, the operation of SMT soldering for the LED strip can be completed quickly.