Connector Assembly Light Pipe Status Indicator
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Solution Overview
Problem
Existing connector assemblies with LED status indicators require transparent plastic housings, which are costly to manufacture, and there is a need for a more cost-effective solution to indicate the normal status between complementary connectors.
Innovation Solution
A connector assembly design featuring a housing with conductive contacts, a circuit board with LEDs, and a rear cover with light pipes to spread light emitted by the LEDs outwardly, indicating the normal status between the power connector assembly and a complementary connector, using a combination of conductive and resin materials to reduce manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the housing is made wholly of transparent material to allow LED light to pass through for status indication, then the status indicator function is achieved, but the manufacturing cost increases
Solution Approach 1:
The housing is divided into two parts: a non-transparent main housing body and a transparent rear cover. The transparent rear cover is specifically positioned at the LED light emission path to allow status indication, while the main housing remains non-transparent for cost-effectiveness and structural integrity. This segmentation resolves the contradiction by applying transparency only where functionally necessary.
Solution Approach 2:
The rear cover is made of transparent material specifically at the location where LED light needs to pass through for status indication, while other portions of the housing use cost-effective non-transparent materials. This local application of transparency achieves the status indicator function without requiring the entire housing to be transparent, thereby reducing manufacturing costs.
2Illumination intensity
If light pipes are added to spread LED light outwardly for better status indication, then the visibility of status indicator is improved, but the device complexity increases
Solution Approach 1:
The light pipe function is integrated into the rear cover itself, making the rear cover serve dual purposes: protecting internal components and guiding/spreading LED light outwardly. By combining the light pipe function with the existing rear cover structure, the patent improves light visibility without significantly increasing device complexity.
Solution Approach 2:
The rear cover is designed to perform multiple functions simultaneously: it protects internal components (circuit board, LED, cable connections) and acts as a light guide to spread LED light outwardly for status indication. This multi-functionality reduces the need for separate light pipe components, thereby improving visibility while minimizing structural complexity.
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 proposed design effectively indicates the normal status of the connector assembly using LEDs and light pipes, reducing manufacturing costs by utilizing a combination of conductive and resin materials, while maintaining the functionality of the LED status indicator.
Implementation Method 1
status indicator means aligning with the LED of the circuit board and enclosed by the rear cover to spread the light emitted from the LED outwardly for indicating normal status
Data Source
AI summary
A power connector assembly (100) includes a housing (2) defining a number of passages (23, 24), a circuit board (4) assembled to the housing and including a pair of LEDs (42) capable of being actuated to emit light, a number of contacts respectively received in the passages of the housing, a cable (6) electrically connecting with the circuit board, a rear cover (7) assembled to the housing to enclose the contact, the circuit board and front end of the cable, and status indicator means (81, 82) aligning with the LED of the circuit board and enclosed by the rear cover to spread the light emitted from the LED outwardly for indicating normal status between the power connector assembly and a complementary connector. The contacts include a power contact (31), a ground contact (32) electrically connecting with the circuit board and a detect contact (33) electrically connecting with the LED of the circuit board.