U-Shaped Light Strip Connectors for Sagging Prevention
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Solution Overview
Problem
Existing elongated light systems, such as light strips, face challenges in stability, particularly at the connections between support rails, which can lead to sagging and reduced rigidity, making it difficult to produce long, robust light bands.
Innovation Solution
A system with U-shaped support rails and connectors featuring longitudinal guides that allow for a positive, non-positive connection, ensuring optimal alignment and fixation of the connector within the support rails, using sheet metal components with specific forming processes to enhance stability and prevent spring effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If connectors are inserted into support rails to create long light strips, then the length of the light strip is increased, but the stability and rigidity at connection points deteriorate, causing sagging
Solution Approach 1:
The connector is divided into distinct functional segments: insertion portions that engage with the support rails, a connection portion that joins multiple rails, and holding portions with vertically extending linear sections that provide structural support. This segmentation allows each part to perform its specific function optimally, maintaining rigidity while enabling extended length.
Solution Approach 2:
The holding portions extend vertically (in the Z-direction) between upper and lower guide ends, adding a vertical dimension to the connection structure. This vertical extension creates a three-dimensional connection geometry that significantly enhances bending stiffness and resistance to sagging, transforming a potentially weak planar connection into a robust spatial structure.
2Stability of the object's composition
If robust connectors are used to improve stability, then the stability improves, but the device complexity increases
Solution Approach 1:
The connector is designed as a multi-functional integrated component that simultaneously provides insertion engagement, lateral connection, vertical support, alignment guidance, and mechanical locking. The holding portions with linear sections serve both structural support and alignment functions, reducing the need for separate components and simplifying the overall system while maintaining high stability.
Solution Approach 2:
Multiple functional elements are merged into a single connector body: the insertion portions for engaging support rails, the connection portion for joining rails, and the holding portions for vertical support are integrated into one monolithic structure. This merging reduces assembly steps and component count while achieving robust connection through the coordinated action of integrated features.
3Manufacturing precision
If connectors are made from sheet metal with specific forming processes, then the manufacturing precision and stability are improved, but the ease of manufacture decreases
Solution Approach 1:
The connector design incorporates specific geometric parameters: vertically extending linear sections in the holding portions between upper and lower guide ends, and defined angular relationships between walls. These parameter specifications ensure precise alignment and stable connection, while the sheet metal forming process transforms flat stock into the three-dimensional structure through controlled bending and shaping operations.
Data Source
Figure 1a~1b
Figure 2~3
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AI summary
The invention relates to a system 1 for realizing a luminaire elongated in a longitudinal direction X, the system 1 comprising at least two longitudinally elongated support rails 21, 22 and at least one longitudinally elongated connector 10 for mechanically connecting two longitudinally elongated support rails 21, 22 next to each other, wherein the support rails 21, 22 and the connector 10 each have a cross-section perpendicular to the longitudinal direction X in the form of a kind of U with a base 213, 223, 103 and two side walls 211, 212, 221, 222, 101, 102. The side walls 101, 102 of the connector 10 each comprise a holding section 110 extending in a straight line along the vertical Z, which is bounded by an upper 111 and a lower end 112, wherein in the operating position the upper 111 and the lower end 112 of the straight holding section 110 bear against the upper 217 and lower guide end 218 of the longitudinal guide.