Light Strip Contact System with Force-Fit Finger
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Solution Overview
Problem
The existing manufacturing and assembly processes for light strips are complex, labor-intensive, and difficult to automate due to the need for direct cable connections between the mounting rail and protective conductor, requiring stripping and additional wiring, which complicates the establishment of safe and efficient electrical connections.
Innovation Solution
A contacting system with a current-carrying profile and a contact device featuring a conductive contact finger that forms a force-fit connection with the mounting rail, scraping off the insulating lacquer to establish an electrically conductive link, eliminating the need for additional connecting devices and ensuring connection to the protective conductor for safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If direct cable connections are used between the mounting rail and protective conductor, then reliable electrical connection is achieved, but manufacturing complexity and labor intensity increase significantly
Solution Approach 1:
The patent combines the protective conductor connection function with the existing mounting rail structure by integrating a contact element directly into the rail. This merging eliminates the need for separate cable connections and additional wiring steps, reducing manufacturing complexity while maintaining reliable electrical connection between the mounting rail and protective conductor.
Solution Approach 2:
The mounting rail is designed with an integrated contact element that automatically establishes electrical connection with the protective conductor when the device is installed. This self-service mechanism eliminates the need for manual stripping and wiring operations, reducing labor intensity while ensuring reliable connection without additional manufacturing steps.
2Reliability
If manual stripping and wiring operations are performed, then proper electrical connections are established, but productivity decreases and automation becomes difficult
Solution Approach 1:
The contact element is pre-integrated into the mounting rail structure, automatically establishing electrical connection upon installation. This eliminates manual stripping and wiring operations entirely, enabling automated assembly processes while maintaining safe and reliable electrical connections between the protective conductor and mounting rail.
Solution Approach 2:
The electrical connection capability is prepared in advance during the manufacturing of the mounting rail, with the contact element already positioned and configured. This preliminary action eliminates the need for time-consuming on-site wiring operations, significantly increasing assembly speed and enabling automation while ensuring connection safety.
3Reliability
If additional connecting devices are used for protective conductor connection, then connection reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The protective conductor connection function is merged into the existing mounting rail structure through an integrated contact element. This eliminates the need for additional separate connecting devices, reducing the number of components and simplifying the overall device structure while maintaining reliable protective conductor connection.
Solution Approach 2:
The mounting rail is designed to perform multiple functions: mechanical support, electrical power distribution, and protective conductor connection. By integrating the contact element into the rail, the system achieves multi-functionality without adding separate components, reducing device complexity while ensuring reliable protective conductor 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
Simplifies the production and assembly of light strips by enabling tool-free, forced electrical connections between the current-carrying profile and the mounting rail, ensuring reliable and safe connections without additional tools or steps, reducing labor and increasing efficiency.
Implementation Method 1
The contact finger makes contact in the intermediate space and has at least one partially electrically conductive surface layer. An electrically conductive connection between the electrically conductive line of the current-carrying profile and the mounting rail is established via this at least partially electrically conductive surface layer of the contact finger.
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
The system (1) has a current feed section (21) with a projection (22) which has an electrically conducting line which is partially open, at a side facing a bar section (5). A contact device (10) e.g. supplier, laterally contacts the line by a contact finger (31) for forming an electrically conducting contact, where the finger partially has an electrically conducting surface layer. Light width of an intermediate area is less than or equal to width of the finger. An electrically conducting connection is established between the line and a mounting rail partially over the layer of the finger.