Light Strip Insert With Linear Cam Contacts for Reliable Wiring
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Solution Overview
Problem
Existing rotary mechanisms in linear lighting systems often result in uneven contact pressure, mechanical wear, and require specialized tools for installation, leading to unreliable electrical connections and increased maintenance costs.
Innovation Solution
A spring-loaded insert with a linearly displaceable cam element that deflects electrical contact elements to establish a symmetrical and reliable connection, eliminating the need for rotary mechanisms and simplifying installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a rotary mechanism is used to bring contact elements into contact with conductors, then installation is simple and quick, but the contact pressure is uneven and the electrical connection becomes unreliable
Solution Approach 1:
Instead of using a rotary mechanism that rotates contact elements into position, the patent inverts the approach by using a linearly displaceable cam element that pushes spring-loaded contact elements directly against the conductors. This linear displacement mechanism ensures uniform contact pressure across all contact elements, resolving the reliability issue while maintaining ease of installation through a simple push-in motion.
Solution Approach 2:
The patent introduces spring-loaded contact elements that dynamically adapt to the conductors' positions. The springs provide continuous contact pressure and compensate for manufacturing tolerances or conductor position variations, ensuring reliable electrical connection. The cam element's linear displacement dynamically actuates these springs, combining simplicity of operation with connection reliability.
2Productivity
If a rotary mechanism is used to deflect contact elements, then installation is quick, but mechanical stress wears down contact elements and conductors, shortening system lifespan
Solution Approach 1:
The patent replaces the rotary deflection mechanism with a linear displacement cam element that pushes contact elements directly against the conductors. This eliminates the rotational motion that causes mechanical stress and wear, thereby extending system lifespan while maintaining quick installation through a simple linear pushing action.
Solution Approach 2:
The patent substitutes the rotary mechanical system with a linear mechanical system. The cam element's linear displacement replaces the rotary motion, reducing mechanical stress on contact elements and conductors. This substitution maintains installation speed while significantly improving durability and extending system lifespan.
3Ease of operation
If a rotary mechanism is used for contacting elements, then installation is simple, but the system is susceptible to mechanical malfunctions in vibrating or shock-prone environments
Solution Approach 1:
The patent inverts the rotary mechanism approach by using a linearly displaceable cam element with spring-loaded contact elements. This linear configuration is inherently more resistant to vibration and shock, as it lacks the rotational joints and bearings that are prone to malfunction in harsh environments. Installation remains simple through the push-in motion of the cam element.
Solution Approach 2:
The spring-loaded contact elements provide dynamic compliance that absorbs vibrations and shock impacts. The springs can compress and rebound, accommodating mechanical disturbances without causing malfunction. This dynamic response maintains reliable electrical connection in vibrating or shock-prone environments while keeping the installation process simple.
4Ease of operation
If a rotary mechanism is used, then contact elements can be positioned by rotation, but specialized tools and expertise are required for installation and maintenance
Solution Approach 1:
The patent replaces the rotary positioning mechanism with a linear displacement cam element. This simplifies the installation process to a basic push-in motion that does not require specialized tools or expertise. The linear cam mechanism is easier to manufacture and maintain compared to rotary mechanisms with multiple moving parts, directly addressing the complexity issue while preserving contact positioning capability.
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 provides a robust, reliable, and compact electrical connection with improved mechanical stability and ease of installation, reducing the risk of contact failures and extending the system's lifespan.
Implementation Method 1
several spring-loaded electrical contact elements (6), which can be deflected by the cam element (8)
Data Source
Figure 1~2
Figure 3a~3b
AI summary
The invention relates to an insert for a linear lighting system, wherein the insert is designed to be inserted into a rail of the linear lighting system and to contact a multi-core electrical through-wiring system arranged inside the rail, wherein the insert comprises an electrical adapter (2) having a housing (4), several spring-loaded electrical contact elements (6) and a linearly displaceable cam element (8), wherein the cam element (8) is displaceable in the housing (4) along a direction parallel to the longitudinal extent of the rail and has at least one chamfer (10) which is designed to deflect the electrical contact elements (6) when the cam element (8) is moved, wherein the electrical contact elements (6) protrude from one or more openings (12) of the housing (4) in the deflected state to contact the conductors of the through-wiring system.