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在LED照明中进行正确的连接

Sept. 12, 2012
尽管照明被视为相对简单的应用,但选择合适的连接器类型和建筑材料可能是一个挑战。

LED照明在增长方面点燃了电子行业:根据研究公司策略无限,基于LED的灯和照明器市场增长了69%,至94亿美元。期望值显示从2011年到2016年的每年20%的膨胀率,商业和工业照明部门领导了这一指控。

这种增长趋势不仅包括光源的范围。这也意味着支持电子的性质,尤其是连接器的性质。他们需要将许多LED组合到集成的发射极或模块中,并与来自外界的功率和控制信号连接到所得的光源。

Though historically known to be electronically simple, lighting applications are, by virtue of their ubiquity, extremely diverse. This means that the components involved often must fit two sets of design requirements: those earmarked strictly for use in LED lighting, and those necessitated by the circumstances and environment in which the connector will be deployed.

例如,国内领导发射器设计典型ly needs to fit into an existing physical lamp configuration, presenting special size and thermal-management constraints. However, a product intended for outdoor use, such as in architectural lighting, will also have to resist moisture ingress and more severe temperature fluctuations.

LED照明应用程序的一组设计要求集通常围绕尺寸限制和成本压力,因为照明解决方案正在从纯电气转移到电子。在这方面,简单性很重要 - 人们期望更换灯泡很容易,他们认为易于范围应该在整个系统中运行。照明还倾向于需要提供长时间使用寿命和相对较少的交配周期的连接器。

标准和照明特定连接选项

在大众市场应用中,LED照明制造商面临着巨大的压力以降低成本。还有压力要创建易于组装的互连系统来维护原位。甚至高效的LED也会在不断扩大的照明环境中消散大量的热量。在持续时期遇到高温时,连接器必须继续可靠地发挥作用。

Thus, despite the fact that lighting is seen as a relatively simple application, choosing the right connector type and construction material can be quite a challenge.

环境和物理形态的多样性为设计师探索创造了多种选择。在频谱的一端,标准的板到板,电线对线和电线之间的互连系统可能是合适的。有时,制造商会专门修改这些版本用于照明应用程序。但是供应商还创建了特定于LED的连接器,通常是特定灯样式的定制组件。

The most important factor is to ensure that the particular application drives the specification. The vast majority of applications can be satisfied with standard connectors, or customised cable assemblies created from these parts. However, a lighting-specific part may be right for a certain situation. For instance, the requirement may be extreme ease of assembly.

户外,舞台和工作室

One well-established area for LEDs is in stage and studio lighting. Lighting designers value LEDs’ greater flexibility in creating special effects whilst eliminating the problems caused by excessive heat and high power consumption of conventional lamps.

这些应用中的挑战通常是将坚固的结构与容易的组装和高交配/贬低公差相结合。至少的IP65/67等级至关重要,连接器的物理设计中的应变减轻程度也是如此,以应对日常使用的风险。

例如,苯酚“ Ecomate”圆形连接器之类的系统非常适合此类要求((图。1。它最初是用于工厂建筑和机器建筑中的开发的,体现了一种用于照明应用的产品类型。


1. Ecomate圆形连接器适用于舞台和工作室照明,无论是在室内还是室外。

该连接器具有坚固的模制外壳,设计用于快速组装。它带有拧紧的电缆腺,夹紧环,合并的应变缓解和安装垫圈,并提供必要的IP65/67等级。

LED lighting also is seeing high adoption rates within the world of architectural lighting. In these applications, the connector often needs to withstand even more extreme conditions, e.g., total water immersion and wide ambient temperature variations. Amphenol LTW’s outdoor waterproof connectors, developed originally for military and aerospace applications, are being repurposed for LED lighting.

特定于照明连接器的专业化

Frequently, LEDs must be fitted into an existing standard form factor, at which point designers can opt for lighting-specific connectors. For this scenario, AVX developed a range of devices for low-power dc-dc interconnects—the9159, 9175, 9176, and 9177 series wire-to-board connectors and the 9608 and 9609 series of board-to-board connectors.

The 9608 and 9609 parts, specifically designed for LED applications, offer a 1.4mm mating height, claimed as the lowest in the industry. The low mating height matches the height of an SMD LED. As such, the connector can be positioned very close to the LED without causing a shadow.

LED照明条中的9159个特殊的西装端到端堆积。条带低3mm的高度和5.5毫米的总配合长度,可以生产非常紧凑的照明产品。连接器的触点在5 a处为125 V AC,配备2到6针,可容纳22至24 AWG的电线尺寸,并且不需要安装的特殊工具。它们具有锁定夹以提高可靠性。

此类别中的另一个参赛者是Hirose DF59多功能系统,其配置文件仅为2.5mm((图2。在电线对板和板上的版本中可用,仅需要一种类型的插座(无论是电缆插头还是板插头),从而减少了所需组件的数量。2至6位连接器的总尺寸为8mm x 9mm,可防止LED照明条中的阴影。


2. Hirose DF59连接器的低调仅为2.5mm。

虽然外形通常在照明应用中是绝对的限制,但需要维持安全标准。特别是,当使用电源电源时,设计师必须意识到爬行(沿表面的绝缘距离)和间隙(通过空气的绝缘距离)。像许多连接器范围一样,Hirose DF59具有2mm或4mm的音高,可满足这些要求。

如前所述,快速简便的组装通常是照明市场中的重中之重。例如,无焊接互连系统有助于加速和脱颖而出的组装任务,从而降低了创建LED发射极和模块组件的成本。

沿着这些线路,TE连接开发了SMIZ系列无焊LED插座,该插座旨在与Sharp的Mini Zenigata LED一起使用。它们允许LED使用两个标准的M2螺钉直接连接到散热器上。同样,该公司的戳线连接器在LED照明灯具中易于组装。它们以1或2杆的形式,整孔或SMT版本,每个触点为250 V AC,5 A。

A Familiar Feel With Standard Connectors

虽然特定于照明的连接器为定义问题提供了量身定制的解决方案,但许多设计师希望在可能的情况下坚持使用。照明应用的巨大多样性以及大量的标准连接器类型组合意味着通常有适合目的的标准产品。

也许连接器的高度并不是一个关键的考虑因素,但是人们希望最大程度地减少库存。SAMTEC提出了这种情况的雌雄同体板上的自我制作和板上的电源连接器((图3。These shrouded and polarised connectors minimise the number of discrete parts within the interconnect system. An audible click confirms that they’re properly mated, speeding up assembly.


3. Hermaphroditic self-mating connectors, developed by Samtec, help reduce inventory. They produce an audible click to confirm a good connection.

在其他情况下,甚至更熟悉的连接器(例如,DIN 41612和D型)也可用于固态照明。标准色带连接器也是如此。例如FCI的FFC/FPC/CIC家族中的那些。该公司的模块化插孔经常用于智能LED模块之间的数据和电力以上(POE)连接。

特定应用的特殊需求

许多应用程序都提出了非常特殊的连接要求。除了安全标准和批准所驱动的特殊要求之外,汽车和路边照明别无所求。这些要求通常掩盖了从连接器与LED的使用中得出的规范元素。

例如,Molex的被动安全孔连接器((图4was designed to meet new European requirements, which state that all roadside lighting and electrified signage must have a power quick-disconnect system. Much of this lighting and signage is now LED-based to reduce operating costs, both through saving energy and reducing maintenance requirements. To comply with the legislation, the connector system must disconnect the electrical supply to the pole or sign within 0.4 seconds of an impact.


4. Molex安全孔连接器旨在在任何影响的0.4秒内断开电源。

Molex的连接器是IP68密封的,并带有防水盖和内置的杆子固定带,并用电缆预组装。它们是为街道照明,交通信号灯,交通柱或柱子或道路上任何其他功率耗尽系统而设计的。

通常,设计师制造和使用LED照明产品的挑战不是在寻找合适的连接器,而是从无数选择中选择正确的部分。在这里,一个好的分销商熟悉各种制造商的连接器的比较优势和劣势,可以帮助简化创建一个具有成本效益,可靠的LED照明系统的过程。

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