Connector Assembly with Inner Cavity for Lighting Systems
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Solution Overview
Problem
Connector assemblies in the lighting field face issues such as stress-induced failures like overheating, overload, and poor contacts due to thermal expansion and misalignment of illumination elements, which current cable-based solutions cannot effectively address without compromising aesthetics.
Innovation Solution
A connector assembly with a connection element, mounting member, and sealing elements that form an inner cavity to accommodate a cable, reducing stress through a defined gap and sealing to prevent contaminants and allow for movement, thereby securing the connection while maintaining a neat appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cable-based connector assemblies are used to avoid stress between connectors, then reliability is improved, but device complexity increases and aesthetic appearance deteriorates due to exposed cables
Solution Approach 1:
The cable is nested within the connector housing, forming an integrated assembly where the cable extends through the connection element and is contained within the housing structure. This nesting eliminates exposed cables while maintaining the stress-absorbing cable connection, resolving the contradiction between reliability and aesthetics/complexity
Solution Approach 2:
The connector housing integrates multiple functions: it provides structural support, contains the cable routing, houses the connection elements, and seals the internal cavity. By merging these functions into a single integrated component rather than separate parts, the design improves reliability while reducing overall device complexity and achieving a neat appearance
2Manufacturing precision
If rigid connector assemblies are used to maintain alignment, then manufacturing precision is improved, but reliability deteriorates due to stress from thermal expansion and misalignment
Solution Approach 1:
The connector assembly incorporates dynamic elements that allow movement and adjustment: the cable provides flexibility to accommodate thermal expansion, the mounting member includes a gap that allows positional adjustment, and the overall structure permits slight misalignments without causing stress. This dynamic design maintains reliability while accepting reasonable manufacturing tolerances
Solution Approach 2:
The design anticipates thermal expansion and alignment variations by incorporating a cable with sufficient length and flexibility before assembly. The cable acts as a pre-built cushion that absorbs expected dimensional changes and misalignments, preventing stress buildup that would otherwise lead to connector failure
3Volume of moving object
If connectors are positioned close together to achieve compact design, then volume is reduced, but reliability deteriorates due to increased stress between connectors
Solution Approach 1:
The cable is nested within the connector housing, allowing the connection assembly to be compact without requiring additional space for external cable routing. This nesting enables close positioning of connectors while maintaining the stress-absorbing cable connection inside the housing volume
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
The solution minimizes failure risks by absorbing thermal expansion and alignment stresses, preventing overheating, overload, and maintaining reliable contacts between connectors, while maintaining a compact and aesthetically pleasing design.
Implementation Method 1
a first sealing element coupled to the mounting member and the connection element, and configured to seal the first gap around a first longitudinal end of the mounting member
Implementation Method 2
a second sealing element coupled to the mounting member and the cable, and configured to seal a second gap between a second longitudinal end of the mounting member and the cable
Implementation Method 3
the huge stress between connectors is caused by the thermal expansion & contraction of the illumination elements
Data Source
AI summary
A connector is provided to be assembled on a first illumination element and configured to be releasably coupled to a mating connector on a second illumination element. The connector includes a connection element comprising a conductor. The conductor comprises a first end coupled to a cable extending through the connection element, and a second end is releasably connected to an end of a mating conductor of the mating connector. A mounting member is configured to secure the connection element to the first illumination element, and a first gap is defined between an internal surface of the mounting member and the external surface of the connection element. A first sealing element is coupled to the mounting member and the connection element; and a second sealing element is coupled to the mounting member and the cable.