Plug and Cord Connector with Integrated Circuitry for LED Lighting
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Solution Overview
Problem
Existing plug and cord connector combinations for decorative lighting products, particularly those using LEDs, lack integrated circuitry for current reduction, rectification, and voltage management, leading to increased power consumption, reduced LED lifespan, and the need for additional wires.
Innovation Solution
A plug and cord connector pair with integrated circuitry that includes a printed circuit board within a protective outer shell, capable of full wave AC to DC rectification, current limiting, and voltage reduction, eliminating the need for additional wires and enhancing LED luminous intensity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional control circuits (rectification, current reduction, current limiting, voltage reduction, blinking or flashing circuitry) are added after the plug and cord connector, then the desired electrical control functions are achieved, but cost increases, reliability decreases, manufacturing complexity increases, and appearance is degraded
Solution Approach 1:
The patent combines multiple electrical control functions (rectification, current reduction, current limiting, voltage reduction, blinking, and flashing circuitry) directly into the plug and cord connector housing. This merging eliminates the need for separate after-market circuit additions, thereby reducing manufacturing complexity while maintaining full electrical control versatility. The integrated circuit board within the connector performs all these functions in a single unified component.
Solution Approach 2:
The plug and cord connector is designed as a multi-functional device that simultaneously provides mechanical connection, electrical power transmission, and multiple control functions (rectification, current control, voltage reduction, and lighting effects). This universal design allows a single component to replace what would traditionally require multiple separate components, reducing both manufacturing complexity and overall system complexity.
2Adaptability or versatility
If additional control circuits are added after the plug and cord connector, then the desired electrical control functions are achieved, but cost increases
Solution Approach 1:
By merging all control circuit functions into the plug and cord connector, the patent eliminates the need for separate circuit components and their associated installation, wiring, and assembly steps. This consolidation reduces material costs, assembly labor costs, and quality control costs, thereby reducing overall manufacturing cost while maintaining full electrical control versatility.
3Adaptability or versatility
If additional control circuits are added after the plug and cord connector, then the desired electrical control functions are achieved, but reliability decreases
Solution Approach 1:
The integration of all control circuits within the sealed plug and connector housing reduces the number of external connections, wire harnesses, and assembly interfaces that could potentially fail. This unified design improves reliability by eliminating multiple potential failure points while maintaining full electrical control functionality.
4Adaptability or versatility
If additional control circuits are added after the plug and cord connector, then the desired electrical control functions are achieved, but appearance is degraded
Solution Approach 1:
By integrating all control circuitry within the plug and connector housing, the patent eliminates the need for visible external components, wire bundles, and separate circuit housings that would compromise the aesthetic appearance of the decorative lighting product. The unified design maintains clean lines and proper form factors while providing full electrical control versatility.
5Area of stationary object
If series connections are added to extend light string length, then coverage area increases, but the number of wires required increases
Solution Approach 1:
The plug and cord connector with integrated circuitry is designed to handle multiple series connections through its multi-functional capabilities. The integrated circuit board provides multiple output terminals that can accommodate series-daisy-chained connections without requiring additional external wiring harnesses or connector assemblies, thereby extending coverage area while minimizing wire quantity.
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 reduces electricity consumption, extends LED life, and simplifies manufacturing by integrating necessary circuitry directly into the plug and cord connector, minimizing the number of wires required and improving the reliability and appearance of LED-based decorative lighting products.
Implementation Method 1
integrated circuitry capable of full wave AC to DC rectification
Implementation Method 2
integrated circuitry capable of limiting LED current
Implementation Method 3
integrated circuitry capable of reducing voltage
Data Source
AI summary
A plug and/or a plug and cord connector set that includes integrated circuitry for use with decorative lighting products such as Christmas lights and rope lights. The integrated circuitry included in the plug and/or plug and cord connector combination can serve to reduce or limit current, provide full-wave AC to DC rectification, provide overload protection, reduce voltage, protect against voltage spikes, add blinking or flashing functions, or any combination thereof. An optional intermediate circuit is included for the manufacture of light strings employing multiple series connections.