Surface Mount Contact Cylindrical Lance Design
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Solution Overview
Problem
Conventional surface mount contacts for LED modules suffer from poor assembly efficiency, light distribution degradation, and heat radiation issues due to their design, which leads to enlarged connectors blocking light and requiring larger substrate sizes, counteracting the demand for downsizing.
Innovation Solution
A surface mount contact with a cylindrical shape and a lance that bites into the core wire for connection, eliminating the need for large-diameter portions and shoulders, allowing for efficient assembly and reducing the connector's size, thereby improving light distribution and heat radiation characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a large-diameter portion and shoulder are provided in the contact to guide and stop the electrical wire, then the wire connection is facilitated, but the connector size is enlarged and light distribution characteristics are degraded
Solution Approach 1:
The patent extracts and removes the large-diameter portion and shoulder structures from the contact design. Instead of using these bulky features to guide and stop the wire, the invention relies on the cylindrical portion's geometry and the lance's positioning function, thereby reducing connector size while maintaining wire connection capability
Solution Approach 2:
Instead of using a large-diameter portion to guide the wire from the outside, the invention inverts the approach by using a cylindrical portion with a lance that engages the wire from the inside. The wire is inserted through the opening and positioned by the lance's sharp edge, eliminating the need for external guiding structures
2Reliability
If the contact axial length is increased to provide proper soldering portions, then reliable electrical connection is achieved, but the connector size is enlarged and heat radiation characteristics are degraded
Solution Approach 1:
The patent applies local quality by concentrating the electrical connection function at specific locations (the lance tip engaging the core wire, and the soldering portions at the cylindrical portion ends) rather than requiring the entire contact to be long. This allows reliable connection with minimal axial length
Solution Approach 2:
The invention changes the dimensional approach by extending soldering portions radially outward from the cylindrical portion ends rather than increasing axial length. This allows proper soldering area without increasing the contact's axial dimension, thereby maintaining compact size for heat radiation
3Reliability
If conventional direct solder joining of lead wire to substrate terminal is used, then reliable electrical connection is achieved, but assembly working efficiency is poor
Solution Approach 1:
The patent applies preliminary action by pre-forming the cylindrical portion and lance structure on the contact before assembly. The lance is pre-positioned to automatically engage and secure the core wire upon insertion, eliminating the need for separate crimping or soldering operations during assembly, thereby improving productivity while maintaining reliability
4Illumination intensity
If the connector size is reduced to improve light distribution, then light distribution characteristics are improved, but wire connection and assembly become more difficult
Solution Approach 1:
The patent uses asymmetry in the lance design, where the sharp edge is positioned at an angle relative to the cylindrical portion axis. This asymmetric geometry allows the lance to effectively engage and secure the wire with minimal radial space, maintaining compact connector size while ensuring easy wire insertion and connection
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 enhances assembly efficiency, maintains excellent light distribution, and allows for smaller substrate sizes while extending the creepage distance, improving heat radiation characteristics by minimizing the connector's axial length and mounting area.
Implementation Method 1
the sharp edge 124 formed on the tip of the lance 123 bites into a core wire which projects from the front end of the covering portion of the electrical wire for connecting the electrical wire to the contact 120, and for preventing extraction of the electrical wire
Implementation Method 2
The surface mount soldering portions 125, 126 are solder connected, for example, to the substrate 40 on which the LED module is mounted, or to a conductive pad formed on the substrate 62 made up of the LED package
Data Source
Figure 1~2B
Figure 3A~3B
Figure 4~5
AI summary
A connector includes a housing (10) and a surface mount contact (20). The surface mount contact (20) includes a cylindrical portion (21) formed in a cylindrical shape, into which only a core wire of an electrical wire is inserted. In an intermediate portion of the cylindrical portion (21), a lance (22) is provided, which bites into the core wire of the electrical wire inserted into the cylindrical portion (21) for connecting to the electrical wire, and stopping removal of the electrical wire. At both ends of the cylindrical portion (21), a pair of the surface mount soldering portions (24, 25) are provided for solder connection to a substrate. Each of the pair of the surface mount soldering portions (24, 25) extends in a direction orthogonal to the axial direction and from an end of the cylindrical portion (21).