High-Voltage Linear Lighting Service Loops for Cut-Point Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing high-voltage linear lighting systems face difficulties in connecting exposed conductors after cutting, as they become very short, making it challenging to fit them into crimps or terminal blocks, leading to wastage and increased manufacturing costs.
Innovation Solution
Incorporating 'service loops' in the conductors, which provide additional length for connections when the linear lighting is cut, allowing easier connection to power by forming extra lengths of conductors around cut points, either as Ω-shaped loops or reinforced coils, encapsulated within the transparent flexible covering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the linear lighting is cut to particular lengths, then the linear lighting can be customized to fit specific applications, but the exposed conductors become very short making connection difficult
Solution Approach 1:
Service loops are pre-formed at designated cut points during manufacturing, creating extra conductor length in advance. This preliminary action ensures that when the linear lighting is cut to any length, sufficient conductor length is already available for connection without requiring additional conductor length in the main run.
2Ease of operation
If the exposed conductors are made longer, then connection becomes easier, but usable product length is sacrificed which increases waste and cost
Solution Approach 1:
The conductor system is segmented into two functional parts: the main run conductors that determine usable product length, and service loop conductors that provide connection length. This segmentation allows independent optimization of each function, enabling full utilization of the linear lighting length while providing sufficient conductor for connections.
Solution Approach 2:
Extra conductor length is provided locally at cut points through service loops, rather than uniformly throughout the entire linear lighting. This localized provision of additional conductor length addresses connection needs only where required, maximizing the usable length of the main product.
3Adaptability or versatility
If manual cutting and stripping is used, then flexibility in length selection is achieved, but the connection process becomes complex and time-consuming
Solution Approach 1:
Service loops are pre-formed at designated cut points during manufacturing, creating extra conductor length in advance. This preliminary action ensures that when the linear lighting is cut to any length, sufficient conductor length is already available for connection without requiring additional conductor length in the main run.
Data Source
AI summary
Linear lighting is disclosed. The linear lighting includes a narrow, elongate printed circuit board (PCB). A plurality of LED light engines are disposed on the PCB and are electrically connected to it. The PCB is divided physically and electrically into repeating blocks, which are physically in series with one another and electrically in parallel. A pair of conductors extends the entire length of the linear lighting. Each of the conductors has a service loop corresponding to the position of each of the cut points. A covering encapsulates the PCB and the pair of conductors. The service loops in the conductors provide for additional length of conductor when the linear lighting is cut at a cut point, so that the linear lighting can be connected to power.