Relay Connector for Indirect Circuit Board Coupling and Electrical Isolation
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Solution Overview
Problem
The mechanical and electrical coupling of multiple circuit boards in light source modules for liquid crystal display devices and lighting devices leads to increased size and uneven luminance, posing safety and quality issues due to the need for separate power supply conductors and potential short-circuiting or open defects in LED strings.
Innovation Solution
A relay connector that indirectly couples two circuit boards via a first coupling portion and a second coupling portion, allowing mechanical coupling while maintaining electrical isolation, thereby reducing the physical distance between boards and eliminating the need for extra electrical signal conducting members, and incorporating features like engagement and projecting portions for positioning and gap creation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple circuit boards are mechanically coupled together to form channels, then electrical coupling between boards is achieved, but the physical distance between channels increases leading to uneven luminance and degraded quality
Solution Approach 1:
The invention divides the electrical coupling function from the mechanical coupling function by introducing a relay connector. Circuit boards within the same channel remain mechanically coupled for electrical connection, while channels are separated by the relay connector structure, allowing precise control over inter-channel spacing to maintain luminance uniformity.
Solution Approach 2:
The relay connector acts as an intermediary component that mechanically connects circuit boards while enabling electrical isolation between channels. Its structured design with positioning features ensures proper spacing between channels, preventing luminance unevenness while maintaining reliable electrical connections within channels.
2Stability of the object's composition
If circuit boards are mechanically coupled together, then structural stability is improved, but electrical uncoupling between different channels becomes difficult
Solution Approach 1:
The relay connector segments the system into distinct channel groups that are mechanically connected but electrically isolated. The connector's design with separate coupling portions for different channels allows structural stability while maintaining electrical independence between channels through controlled impedance traces and isolation structures.
Solution Approach 2:
The relay connector serves as an intermediary that provides both mechanical support for structural stability and electrical isolation through its circuit board traces and isolation design. The positioning portions ensure proper alignment while the electrical traces are configured to prevent unwanted coupling between channels.
3Reliability
If the number of channels is increased to reduce the number of circuit boards per channel, then safety is improved through electrical isolation, but the number of power supply conductors increases leading to larger device size
Solution Approach 1:
The relay connector merges multiple functions into a single component: mechanical coupling of circuit boards, electrical isolation between channels, positioning alignment, and structural support. This integration reduces the need for separate power supply conductors and mounting structures, thereby reducing overall device size while maintaining safety through electrical isolation.
Solution Approach 2:
The relay connector is designed as a multi-functional component that simultaneously provides mechanical support, electrical isolation, positioning, and structural stability. This universal design eliminates the need for additional dedicated components for each function, reducing the overall device volume while ensuring safe electrical isolation between channels.
4Ease of manufacture
If circuit boards are directly mechanically coupled, then assembly is simplified, but unnecessary space is created between boards leading to increased device size
Solution Approach 1:
The relay connector combines the functions of mechanical coupling and space optimization into a single integrated component. The positioning portions and coupling structures are designed to minimize gaps between circuit boards while maintaining ease of assembly, thereby reducing unnecessary space without complicating the manufacturing process.
Data Source
AI summary
A relay connector that is interposed between two substrates provided with mutually connectable connecting parts and that indirectly connects the two substrates, wherein the relay connector is provided with a first connecting part capable of mechanistically connecting to the connecting part of one of the substrates, and a second connecting part capable of mechanistically connecting to the connecting part of the other substrate.