Co-planar LED Strip Interconnect with Compressible Pogo Pins
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Solution Overview
Problem
Existing interconnect solutions for LED boards lack tolerance allowances, current capacity, compactness, and ease of assembly, making them unsuitable for efficient manufacturing and deployment in thin or low-profile illumination applications.
Innovation Solution
A light-emitting diode (LED) lighting strip assembly is designed with an interconnect board and two LED boards, utilizing compressible electrically conductive members like pogo pins to establish electrical connections, allowing for misalignment tolerance and efficient current carrying, while maintaining a low profile and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rigid interconnect methods are used to connect LED boards, then electrical connection is established, but misalignment tolerance is poor and assembly difficulty increases
Solution Approach 1:
The patent uses spring-loaded compressible electrically conductive members instead of rigid connectors. The spring mechanism provides dynamic compliance that automatically adjusts to misalignments between LED boards, maintaining reliable electrical contact while accommodating positional variations during assembly.
Solution Approach 2:
The patent changes the mechanical properties of the interconnect members from rigid to compressible. By using spring-loaded members with controlled compliance, the system transforms the interconnect from a rigid fixed-position connector to a compliant component that can adapt its position within a range, thereby tolerating misalignments.
2Power
If multiple LED boards are connected end-to-end with traditional methods, then current capacity is limited, but interconnect complexity increases
Solution Approach 1:
The patent combines multiple electrical connection functions into a single integrated spring-loaded connector. Each compressible electrically conductive member simultaneously provides mechanical connection, electrical conduction, and misalignment compensation, eliminating the need for separate components and reducing overall interconnect complexity while maintaining high current capacity.
Solution Approach 2:
The spring-loaded compressible members serve multiple functions: they provide mechanical support, establish electrical contact, accommodate misalignments, and allow for board separation if needed. This multi-functionality reduces the number of components required and simplifies the overall interconnect design while handling high current demands.
3Strength
If LED boards are connected with thick interconnect structures, then current capacity and structural strength are improved, but profile height increases
Solution Approach 1:
The spring-loaded compressible members are nested within recesses or cavities in the LED board structures. When compressed, the springs fit within the board thickness, allowing the interconnect mechanism to be contained within the existing board profile rather than extending outward, thus maintaining a low overall profile while providing robust mechanical and electrical connection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables efficient assembly and maintenance of LED lighting strips with improved uniformity and reliability, accommodating misalignments and high current capacity within a compact, low-profile format, enhancing manufacturing efficiency and visual aesthetics.
Implementation Method 1
each compressible electrically conductive member of the first LED board is pressed into electrically conductive contact with the corresponding one of the first electrically conductive pads
Data Source
AI summary
LED board interconnect schemes for illuminable assemblies are provided. Multiple LED boards may form a partial perimeter along an illuminable assembly. The multiple LED boards and interconnects must fit within a limited width and height of the illuminable assembly. In some implementations, an interconnect board and spring connectors are used to provide a low-profile electrical interconnection while maintaining co-planarity of the LEDs across the LED boards.