Perpendicular LED Connector for Wire Insertion
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Solution Overview
Problem
Existing LED lighting fixtures face difficulties in efficiently connecting electrical wires due to the need for precise parallel alignment and insertion into connection devices, which can be challenging and may interrupt the light distribution surface.
Innovation Solution
An LED connector assembly featuring a cylindrical connector with a press-fitted contact that allows for perpendicular insertion of electrical wires, eliminating the need for soldering or crimping and reducing the risk of wire contact with the base during assembly, while maintaining efficient electrical connection and minimizing visual interference with light emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the electrical wire is arranged close to the lamp holding stage to avoid interrupting light distribution, then the light distribution is improved, but the connection operation becomes difficult requiring precise parallel alignment
Solution Approach 1:
The connector provides a conductor receiving passageway that extends in a direction substantially perpendicular to the lamp holding stage surface, allowing the electrical wire to be inserted from the perpendicular direction rather than requiring parallel alignment with the stage surface. This dimensional change in insertion direction resolves the contradiction by enabling easy connection operation while maintaining the wire's position away from the light distribution face.
2Ease of manufacture
If the electrical wire is inserted parallel to the lamp holding stage surface, then the connection can be made, but the wire may contact the base and the operation becomes complex
Solution Approach 1:
The conductor receiving passageway is configured to receive the electrical wire from a direction substantially perpendicular to the lamp holding stage, rather than requiring parallel insertion. This perpendicular insertion path guides the wire through the base thickness without the wire contacting the base surface, eliminating the reliability risk while simplifying the manufacturing operation.
Solution Approach 2:
The connector housing acts as an intermediary structure that provides the conductor receiving passageway, mediating between the lamp holding stage and the electrical wire. This intermediary component guides the wire through a safe perpendicular path, preventing direct contact with the base while facilitating reliable electrical connection.
3Device complexity
If a poke-in connector is used without soldering or crimping, then the manufacturing complexity is reduced, but the connection difficulty increases due to alignment requirements
Solution Approach 1:
The connector maintains the simple poke-in design without soldering or crimping, but changes the insertion direction to perpendicular relative to the lamp holding stage. The conductor receiving passageway is oriented to accept the wire from this perpendicular direction, allowing the simple connector design to achieve easy operation by eliminating the need for precise parallel alignment with the stage surface.
Data Source
AI summary
An LED connector assembly having a LED module, a base. and a connector. The LED module includes a substrate provided with a conductor pattern and an LED device disposed on a surface of the substrate and connecting to the conductor pattern. The base includes an attachment side larger than the LED module and attaching with the LED module such that a bottom surface of the LED module faces the attachment side. The connector that includes a housing fixed to the base, wherein the housing includes a cylindrical section with a conductor receiving passageway at a tip thereof to which the cylindrical section penetrates the base from the attachment side there through, and a contact having one end that connects to the conductor pattern and extend inside the cylindrical section for connection with an electrical wire insertable into the cylindrical section.