Connector-Supported Light Pipe for LED Visibility
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Solution Overview
Problem
Existing electrical assemblies that use light emitting diodes (LEDs) for visual indication face challenges in providing a clear view of the light due to LEDs being obscured by other components, and light pipes often require special modifications to the outer cage, potentially interfering with heat sinks.
Innovation Solution
An electrical assembly design that incorporates a guide frame with cavities to house components, a light pipe with an optical conduit to direct LED light, and a heat sink that can accommodate the light pipe, allowing for secure mounting and clear visibility of the light while minimizing interference with other components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If light emitting elements (LEDs) are electrically connected to the substrate surface, then they can be integrated with other components, but they become obscured from view
Solution Approach 1:
A light pipe is introduced as an intermediary component between the LED and the external environment. The light pipe receives light from the LED at its proximal end and transmits it to a distal end that extends through the guide frame, allowing the light to be visible without the LED itself being exposed. This mediator solves the contradiction by decoupling the LED's position (integrated on substrate) from the light's visibility (extending through frame).
2Reliability
If light pipes are mounted to the outer cage for support, then they can be securely positioned, but special modification to the outer cage is required and heat sink attachment is interfered with
Solution Approach 1:
The light pipe mounting function is merged with the electrical connector housing. The retainer that secures the light pipe is integrated into the connector housing structure, eliminating the need for separate mounting modifications to the guide frame. This combines the support function with an existing component, avoiding additional complexity in the outer cage while maintaining secure mounting.
3Difficulty of detecting and measuring
If light pipes extend through the guide frame for visibility, then light can be viewed clearly, but they interfere with heat sink attachment
Solution Approach 1:
The light pipe is routed through a vertical dimension by extending through the connector housing, which is mounted on the substrate. This allows the light transmission path to occupy a different spatial dimension that does not conflict with the horizontal placement of heat sinks on the guide frame, thereby achieving visibility without interfering with thermal management components.
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 enables clear visual indication of LED operation without modifying the outer cage and minimizes interference with heat sinks, ensuring effective light transmission and efficient heat dissipation.
Implementation Method 1
Light pipes can be used to transport light emitted from LEDs at the surface of an underlying substrate to a position that is easily viewable
Implementation Method 2
The heat sink can have a heat sink body and cooling members that extend from the heat sink body
Data Source
AI summary
An electrical assembly includes a guide frame with closed and open ends, the guide frame configured to be mounted to a substrate. The guide frame defines at least one cavity configured to receive an electrical component therein. A connector housing configured to be disposed in the at least one cavity and mounted to the substrate can support a retainer that extends outwardly from a body of the connector housing. The retainer can be configured to receive an attachment member supported by a light pipe, and can extend outwardly through the closed end of the guide frame. A heat sink coupled to the guide frame can be configured to have at least a portion of the light pipe disposed therein.