Piercing Electrical Connector for Flexible LED Strip Seal
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Solution Overview
Problem
Existing electrical connectors for flexible LED strips face challenges in providing a simple and reliable connection between electrical conductors and the conductive pads on the printed circuit board (PCB) within the flexible material, while also being cost-effective.
Innovation Solution
A metal-bodied electrical connector with a movable plastic contact casing that uses piercing contact elements to establish contact pressure with the PCB pads, combined with a flexible hood and conductor casing for secure conductor engagement, ensuring consistent contact pressure through engagement mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional electrical connector design is used, then the connection structure becomes complex and costly, but the electrical connection between conductors and PCB pads becomes unreliable
Solution Approach 1:
The connector is divided into distinct functional components: a body portion that interfaces with the PCB pad, contact elements that pierce through the flexible material, and conductor receptacles that receive electrical conductors. This segmentation allows each component to be optimized for its specific function while simplifying the overall assembly process and reducing manufacturing complexity.
Solution Approach 2:
The contact elements are designed to automatically pierce through the flexible material and establish electrical contact with the PCB pad when the connector is assembled. This self-piercing mechanism eliminates the need for complex alignment systems or manual insertion processes, reducing both device complexity and assembly steps while ensuring reliable electrical connection.
2Ease of manufacture
If a simple connector design is used, then manufacturing cost is reduced, but contact pressure consistency between contact elements and PCB pads deteriorates
Solution Approach 1:
The contact elements are designed with specific geometric parameters including piercing tip angle, contact surface area, and elastic deformation characteristics. By optimizing these parameters, the contact elements can consistently apply the necessary pressure to maintain reliable electrical contact with the PCB pads while being manufactured using simple, cost-effective processes.
Solution Approach 2:
The contact elements are designed as simple, replaceable components that can be manufactured at low cost. Their straightforward geometry allows for economical production methods while ensuring adequate service life for the intended application, balancing manufacturing simplicity with functional reliability.
3Ease of operation
If piercing contact elements are used, then electrical contact is achieved simply through contact pressure, but the flexible material structure is damaged during assembly
Solution Approach 1:
The piercing contact elements are pre-positioned within the connector body at precise locations and orientations before assembly. This preliminary positioning ensures that when the connector is assembled, the piercing action occurs at the correct location through the flexible material, establishing electrical contact while minimizing damage to surrounding areas and maintaining material integrity.
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 enables a reliable and cost-effective electrical connection by maintaining necessary contact pressure between the connector's contact elements and the PCB pads, ensuring stable power transmission to the LEDs while being easy to assemble and maintain.
Implementation Method 1
a plurality of electrical contact elements carried by the contact casing and having piercing ends which pierce the material of the strip and come into contact with said conductive pads
Implementation Method 2
said metal body and said contact casing having cooperating engagement means which hold them in said operative position
Data Source
AI summary
An electrical connector for a flexible LED strip seal comprises a metal body (9) which clamps an end of the strip of flexible material (2) previously covered by a hood made of flexible material (8), and a contact casing (10) made of plastics material mounted on the metal body (9) and movable relative thereto from a raised inoperative position into a lowered operative position in which the contact elements (14) carried by the contact casing (10) pierce the flexible material of said hood (8) and of said strip (2) and contact conductive pads (6) of a PCB (4) incorporated in the LED seal (2).