Low Profile Surface Mount Poke-In Connector for LED PCBs
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Solution Overview
Problem
Current methods for connecting wire leads to printed circuit boards (PCBs) are time-consuming and costly, especially when multiple PCBs are connected in series, and existing connectors can shadow neighboring components, such as LEDs, due to their size and the need for soldering.
Innovation Solution
A low profile surface mounted electrical connector (SMEC) that uses surface mount technology (SMT) for attachment, featuring a housing with a contact mechanism to securely connect wire leads without soldering, allowing for a compact design that does not obstruct LED light emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional wire leads are soldered to PCBs, then electrical connection is established, but the process is time-consuming and costly
Solution Approach 1:
The patent replaces the thermal soldering process with a mechanical insertion system. The poke-in connector allows wire leads to be mechanically inserted into receptacles on the PCB, eliminating the need for soldering equipment and processes. This mechanical substitution dramatically reduces assembly time and enables automated high-speed production.
Solution Approach 2:
The invention extracts the soldering step entirely from the assembly process. By designing a connector that achieves electrical connection through pure mechanical insertion, the patent removes the time-consuming soldering operation, hot air reflow oven processing, and associated quality control steps, leaving only the simple insertion action.
2Reliability
If connectors are made larger to ensure secure connection, then connection reliability improves, but the connector shadows neighboring LED components
Solution Approach 1:
The patent applies local quality by concentrating the connection reliability functions in a highly localized area. The poke-in connector features a precisely engineered receptacle with localized elastic contacts and retaining structures that provide secure mechanical and electrical connection in a minimal space, allowing the rest of the connector to maintain a low profile that does not obstruct LED light.
Solution Approach 2:
The invention transitions from a traditional planar connector layout to a three-dimensional poke-in structure. The wire lead is inserted vertically through the PCB surface, with the connector components arranged in the Z-dimension rather than spreading out in the XY-plane. This vertical arrangement minimizes the horizontal footprint, preventing shadowing of neighboring LED components while maintaining secure connection through the depth dimension.
3Productivity
If automated SMT process is used for attachment, then manufacturing efficiency improves, but the connector must be compatible with standard SMT processes
Solution Approach 1:
The patent designs the poke-in connector to be universally compatible with existing SMT automation equipment. The connector's footprint, placement features, and attachment mechanism are standardized to work with conventional pick-and-place machines and reflow soldering processes, allowing manufacturers to integrate the new connector technology without investing in specialized equipment, thereby maintaining high manufacturing efficiency.
Data Source
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AI summary
A surface mount poke in connector (10) is disclosed for mounting upon a surface of a printed circuit board, and is particularly applicable for printed circuit boards supporting LEDs. The connector (10) has a securing means for engaging an inserted wire lead without the use of solder.