Two-Part Surface Mount Connector for End-to-End LED PCB Assembly
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Solution Overview
Problem
The high cost of replacing existing fluorescent light tube fixtures and circuitry with LED lighting systems in industrial and commercial settings, along with the environmental hazards and disposal issues associated with fluorescent lighting, necessitates a cost-effective and accessible solution for integrating LED lights into conventional fixtures.
Innovation Solution
An LED light assembly featuring a plurality of printed circuit boards with end-to-end electrical connections using a two-component surface mount connector, allowing for easy integration into existing fluorescent light fixtures, resembling conventional tubes and enabling various sizes and power ratings with standard components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If fluorescent light tube fixtures and circuitry are replaced with LED lighting systems, then energy efficiency and operational life are improved, but installation cost and complexity increase
Solution Approach 1:
The LED lighting system is divided into modular segments where individual LED bulbs can be independently replaced without replacing the entire fixture or circuitry. The connector assembly separates the LED bulb from the circuit board, allowing granular replacement of only the failed component.
Solution Approach 2:
A connector assembly acts as an intermediary between the LED bulb and the circuit board, simplifying the replacement process. The connector includes a housing that receives the LED bulb and electrical contacts that mate with the circuit board, serving as a mediator that decouples the replacement complexity from the main system.
2Ease of repair
If fluorescent light tube fixtures are replaced with LED lighting systems, then maintenance costs are reduced, but initial replacement cost increases
Solution Approach 1:
The LED bulb is designed as a disposable, low-cost component that can be easily replaced when failed. The connector housing and electrical contacts are designed to be reused, allowing the expensive parts to be retained while replacing only the inexpensive LED bulb.
Solution Approach 2:
The system allows discarding of the failed LED bulb while recovering and reusing the connector housing and electrical contacts. This selective replacement strategy reduces maintenance costs by minimizing waste of valuable components.
3Reliability
If LED bulbs are securely connected to circuit boards, then electrical connection reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The connector housing and electrical contacts are merged into a single integrated assembly that is pre-assembled and tested. This merging simplifies the manufacturing process by reducing the number of separate components that need to be handled during assembly, while maintaining reliable electrical connections.
Solution Approach 2:
The electrical contacts are pre-positioned and secured within the housing before the final assembly with the LED bulb. This preliminary action ensures proper alignment and secure connection, improving reliability while simplifying the final assembly process.
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
This solution allows for seamless replacement of fluorescent lighting with LED lighting in existing fixtures, reducing maintenance costs and environmental impact while providing long-lasting, energy-efficient lighting solutions.
Implementation Method 1
each of which has at least one LED bulb
Implementation Method 2
a two-component surface mount electrical connector disposed to electrically connect one end of a first LED PCB to an end of a second adjacent LED PCB
Data Source
AI summary
An LED light assembly includes a plurality of LED printed circuit boards (PCB), with each LED PCB having at least one LED bulb and electrical connector pads configured at each opposite end of the boards. A two-component surface mount electrical connector is configured to connect one end of a first LED PCB to an end of a second said LED PCB such that the first and second LED PCBs are electrically connected end-to-end. The connected LED PCBs may be configured in a light tube that includes connector end caps for mounting the light tube in a light fixture.