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Connectors 101: What Lighting Designers Need to Know

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360° termination that maintains a low-impedance path from the cable through the connector to ground. Thermal Considerations Signal applications typically do not require thermal management. Power applications do. Power contacts have a current rating that indicates the maximum current that the contact can continuously carry. This rating is usually based on a 30°C temperature rise on the contact and is based on measurements of a single contact. When multiple power contacts are used in a housing, the allowable current is derated to allow suitable heat dissipation. It is important therefore for the end user to consult the connector's product specification to determine the suitable current de-rating factor when evaluating a connector system. In high-intensity LED applications, the LEDs themselves generate enough heat to require careful consideration to thermal management—typically this is accomplished by a heat sink and sometimes forced air cooling. The challenge of integrating thermal management into a system is an excellent example of why it is important to consider interconnections early in the design process. This often poses unique system packaging challenges since most of the new high- intensity LEDs are small and are often packaged as surface-mount devices (SMD). Integrating the connector system in amongst the LEDs, circuit boards, optics and thermal devices is often quite challenging if left to the end of the design process. Evaluation of the interconnect earlier on in the design process provides for a more tightly integrated, optimized solution that can make assembly and, if needed, repair much more efficient. Beyond the normal electromechanical aspects, new interconnections must also address the special needs of solid-state lighting. These include higher operating temperatures and the ability to provide housings in specific colors so the connector blends into the visible parts of the lighting designer's fixture. Further, for lighting applications, it is often very desirable to use circuit board-mounted connectors with softened edges to minimize shadowing and the possibility of partially occluding the light output of the low profile surface mount LEDs. The Next Step in Connectors So now that we've defined the key elements of a connector, let's expand the definition a bit. From an application standpoint, it is well known that LEDs perform better when operating at lower temperatures. As mentioned earlier, current LED lighting design methodology usually incorporates one or more LEDs onto a circuit board, usually metal clad for thermal reasons. This assembly is then integrated into the fixture by a lighting fixture designer. Throwing out conventional logic that mandates a circuit board in the system, one could combine a heat sink

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