LED Wire Strain Relief Using Hinged Plates
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Solution Overview
Problem
Conventional LED linear modules experience unreliable electrical connections between the PCB and heat sink, leading to potential failure and safety risks due to wire dislodgment and soldering issues, which can cause intermittent connections and electrical shock.
Innovation Solution
A wire strain relief device with a flexible injected portion formed by two parts joined by a living hinge, which folds onto the wire to provide strain relief and is securely attached to an aluminum heat sink using a screw, restricting wire movement and covering wire connections on the PCB.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires are connected to the PCB and heat sink via soldering or contact pads, then electrical connection is achieved, but the connection becomes faulty over time due to wire strain and dislodgment
Solution Approach 1:
The patent introduces a strain relief device as an intermediary component between the wires and the PCB/heat sink assembly. This device includes a clamp mechanism that secures the wires in place, preventing direct strain transmission to the solder joints or contact pads. The strain relief device acts as a buffer that absorbs mechanical stresses, thereby protecting the electrical connection points from failure due to wire dislodgment or solder joint fatigue.
2Ease of operation
If wires are left exposed and movable, then ease of installation is maintained, but safety risks increase due to potential electrical shock from dislodged wires
Solution Approach 1:
The strain relief device incorporates a flexible cover or shell that encloses the wire connections. This flexible covering protects exposed electrical connections from accidental contact, thereby eliminating the electrical shock hazard. The flexible nature of the cover allows it to accommodate wire movements during installation and operation while maintaining continuous protection. The cover can be easily installed over the secured wires, adding a layer of safety without complicating the installation process.
3Reliability
If a strain relief device is added to secure wires, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The strain relief device is segmented into distinct functional components: a clamp mechanism for securing wires, a mounting structure for attachment to the heat sink, and a flexible cover for protection. This segmentation allows each component to be optimized independently and simplifies the assembly process. The clamp mechanism can be pre-assembled and then attached to the heat sink, while the flexible cover can be separately installed. This modular approach reduces overall device complexity by breaking down the strain relief function into manageable, easily assembled parts.
Data Source
AI summary
Provided is a connection housing including a first plate having a connecting member for slidably connecting the first plate to an electrical assembly. The first plate includes a ridge portion formed across a threading path. A second plate has an opening for non-slidably connecting the second plate to the electrical assembly. The second plate includes a valley portion positioned in opposing relation to the ridge portion. The first and second plates are configured for (i) facilitating placement of a wire along the threading path and (ii) folding onto each other to restrict movement of the wire after the folding.