Multi-Reed Plug-In Connector for LED Lamp Pin Stability

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Solution Overview

Problem

Existing plug connectors in lighting equipment, such as LED lamps, suffer from high failure rates due to the limited contact points between pins and reeds, leading to reduced insertion and extraction forces after multiple uses.

Innovation Solution

A plug-in structure featuring multiple sets of reeds with varying clamping forces arranged in a mounting channel to securely hold pins, including first, second, and third reeds distributed circumferentially and crosswise, providing enhanced clamping and resistance to deformation, and manufactured from metal sheets for increased stability and ease of assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional two-point contact connectors are used, then the structure is simple, but the insertion and extraction forces are small and the failure rate increases after multiple uses

Engineering Contradiction:

Improveconnector reliabilityVSAvoidconnector structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The connector is segmented into multiple contact points: multiple reeds in the female plug and multiple pins in the male plug. This segmentation transforms the traditional single-contact-point structure into a multi-contact-point structure, distributing the electrical connection across multiple points to improve reliability while maintaining reasonable structural complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connector design transitions from point contact to line contact by arranging multiple reeds and pins in arrays. This dimensional change from discrete points to extended lines of contact increases the overall contact area and force distribution, enhancing both reliability and structural efficiency

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Force

If multiple reeds and pins are arranged in arrays, then the contact area and force are increased, but the manufacturing precision requirements increase

Engineering Contradiction:

Improveinsertion and extraction forceVSAvoidcontact point alignment precision

Core Design Contradiction:

ForceVSManufacturing precision

Solution Approach 1:

The reeds are designed as elastic components that can dynamically adjust their position and contact force. This elasticity compensates for manufacturing tolerances and alignment variations, allowing the connector to maintain proper contact force even with variations in manufacturing precision

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The elastic properties of the reeds are optimized to provide appropriate contact force within acceptable manufacturing tolerances. By carefully selecting material properties and geometric parameters of the reeds, the design achieves reliable electrical connection without requiring extremely tight manufacturing precision

Inventive Principle:

Principle #35Parameter changes

3Strength

If welding is used to connect the driving circuit board and lamp cap, then the connection is strong, but it is not easy to automate manufacturing

Engineering Contradiction:

Improveconnection strengthVSAvoidautomation difficulty

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The welding process is replaced with a mechanical insertion system using male-female plug connectors. This substitution eliminates the need for thermal welding processes while providing sufficient electrical and mechanical connection strength, enabling straightforward automation through simple insertion and extraction movements

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The connector design allows for self-aligning and self-latching during insertion. The elastic reeds automatically engage with the pins and maintain contact pressure without requiring external fastening mechanisms or complex alignment procedures, simplifying the automated manufacturing process

Inventive Principle:

Principle #25Self-service

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 multi-level reed arrangement increases the plug force and reduces assembly failure rates, maintaining pin straightness and stability while simplifying the structure and manufacturing process.

Implementation Method 1

multiple sets of reeds arranged in the mounting channel at intervals along the length direction of the mounting channel for clamping the pin

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS11631946B2Plug-in structure and a lamp using the plug-in structure

Publication Date: 2023.04.18 SELF ELECTRONICS CO LTD

AI summary

A plug-in structure has at least one set of male plugs and female plugs that are mated, wherein the male plug has a pin, and the female plug includes: a mounting base, which is provided with a mounting channel for inserting the pin; multiple sets of reeds, arranged in the mounting channel at intervals along the length direction of the mounting channel for clamping the pin. A lamp can be made with the plug-in structure. According to the plug-in structure and the lamp with the plug-in structure, the multi-stage reeds are arranged in the mounting channels to clamp the pins, so that the pins can be kept straight and flat and are not prone to deforming, the insertion and extraction force can be increased, and the assembly failure rate can be reduced.