Flat connectors and flexible cables for a glove-mounted LED strip

connectorled stripwearable

About a year ago made a LED-studded glove from flexible LED strip (like https://www.sparkfun.com/products/12027 but without the silicon coating) for a party.

Because I wanted to keep some mobility in the hand, I cut the strip into smaller segments and soldered some ribbon cable in between with some flexing capability.

This worked for about half an hour, but then the connections started breaking. The solder joints themselves were fine, but the teeny-weeny stranded wires in the ribbon cable broke because of the strain. Taking the glove off broke several in one go.

Now I'd like to make a v.2 that would survive slightly longer. I'd also like to avoid soldering all the connections again because there are over a hundred connections to be made. Obviously, stress reduction is key.

If there was some very flat (1-2 mm) connector that I could just clamp on the of the LED strip and a suitable interconnect cable, that would be optimal. But I have no idea what to look for.

(I'm also open to better suggestions on how to implement the connections. I've considered conducting thread but the shortcut risk is too high)

EDIT: Turns out there are such connectors: http://www.aliexpress.com/store/product/free-shipping-10mm-4pin-for-5050-RGB-led-strip-light-LED-Connector/1027020_1544738051.html

Unfortunately I've only found the 2-pin and 4-pin variants, whereas my LED strip has 3 pads.

Best Answer

The key to reducing breakage for your project is to not rely on solder alone to hold down the wire. What type of wire were you using?

I am working on a similar project right now but more as a therapy glove and we are using a very nice flexible braided core wires. This type of wire with proper strain relief using flexible materiels providers a solid connection has stood up to much abuse.

As long as you are leaving plenty of extra wire between the modules with hot glue on top of the solder joint to provide some flexibility before it even begins to pill on the solder you will be fine.