Wire Clamping Connection for LED Power Supply Boards
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing manual welding process for connecting LED light power supplies to light source boards is prone to poor welding quality, low production efficiency, and safety concerns due to the difficulty in controlling soldering amounts, leading to issues like short circuits and unsoldering.
Innovation Solution
A wire clamping-type connection structure is introduced, featuring conductive metal wire clamping grooves on the light source board with 'U' and 'Y' shaped sub-grooves, threading holes, and clamping pieces with elastic elements to securely clamp wires, eliminating the need for manual welding and enhancing adaptability for automatic and semi-automatic production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual welding is used to connect power supply wires to the light source board, then the connection can be achieved, but the welding quality is poor and production efficiency is low due to difficulty in controlling soldering amounts
Solution Approach 1:
The patent replaces the manual welding process with a mechanical clamping system. Wire clamping grooves with elastic clamping pieces mechanically secure the power supply wires to the light source board, eliminating the need for soldering operations. This substitution resolves the contradiction by providing both consistent connection quality through standardized clamping force and high production efficiency through simplified assembly that requires no skilled welding operations.
Solution Approach 2:
The patent introduces wire clamping grooves as an intermediary component between the power supply wires and the light source board. These grooves, equipped with elastic clamping pieces, serve as a mediator that secures the electrical connection mechanically rather than through welding. This intermediary structure ensures reliable electrical contact while enabling fast, standardized assembly that improves both connection quality and production efficiency.
2Reliability
If manual welding is used to connect power supply wires, then the connection can be made, but safety is low due to short circuits and unsoldering caused by uncontrolled soldering amounts
Solution Approach 1:
The patent replaces the welding process with a mechanical clamping system that uses elastic pieces to secure wires in grooves. This eliminates the safety hazards associated with manual welding, such as short circuits from excessive solder and unsoldering from insufficient solder. The mechanical clamping provides consistent, controlled connection force that ensures reliable electrical contact without the risks of improper welding, thereby improving safety while maintaining ease of manufacture through simple assembly.
Solution Approach 2:
The wire clamping grooves are designed with elastic clamping pieces that automatically adjust to secure the power supply wires. When a wire is inserted into the groove, the elastic piece deforms and then rebounds to clamp the wire firmly, creating a self-adjusting, self-securing connection. This self-service mechanism ensures consistent clamping force and reliable electrical contact without requiring skilled welding operations, thereby improving safety while maintaining ease of manufacture.
3Productivity
If wire clamping grooves are used to connect power supply and light source board, then production efficiency is improved, but the structure complexity increases due to additional components
Solution Approach 1:
The patent merges the wire securing function and the electrical connection function into a single integrated structure. The wire clamping grooves are directly formed on or integrated with the light source board, and the elastic clamping pieces are built into the groove structure. This merging eliminates the need for separate wire holders, mounting brackets, or additional fastening components, thereby improving production efficiency through simplified assembly while avoiding excessive structure complexity.
Solution Approach 2:
The wire clamping groove structure serves multiple functions simultaneously: it provides mechanical support for the power supply wires, secures the wires through elastic clamping, ensures electrical contact with the light source board, and enables standardized assembly for automated production. This multi-functionality reduces the need for separate components and simplifies the overall structure, thereby improving production efficiency without significantly increasing device complexity.
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 simplifies the connection process, improves production efficiency, ensures secure wire fixing, prevents sliding, and enhances safety by reducing the risk of poor contact and circuit blockages, making it suitable for automatic and semi-automatic production while maintaining high-quality connections.
Implementation Method 1
one end of one of the clamping pieces is connected to one of the light source boards through an elastic element
Implementation Method 2
the wire clamping grooves are made of conductive metal material
Data Source
AI summary
The invention provides a wire clamping-type connection structure of a power supply and a light source board, which is in the field of lamp manufacturing. A wire clamping-type connection structure between a power supply and a light source board, comprises: a power supply and a light source board connected to the power supply via wires, and each one of the wire clamping grooves welded at one of power input points on the light source board, each of the plurality of threading holes arranged near the power input points on the edge of the light source board and each of the clamping pieces arranged on the plurality of threading holes.