Electrical Connector Signal Display Unit SMD LED Manufacturing
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Solution Overview
Problem
Conventional electrical connectors require complex and labor-intensive manual processes for manufacturing the signal display unit, including bending and cutting LED pins, which are costly and result in unstable quality and inefficiency, especially when producing connectors with different structures.
Innovation Solution
The electrical connector features a signal display unit with a surface-mounted-device (SMD) LED electrically coupled to a signal display circuit board, eliminating the need for manual bending and gluing, allowing for simplified manufacturing and enabling automatic mass-production with improved product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional LED pins are bent manually to fit the connector structure, then the LED can be installed in the desired position, but the manufacturing process becomes complex and labor-intensive
Solution Approach 1:
Instead of bending the LED pins to fit the connector structure, the patent inverts the approach by designing the connector housing with a pin receiving structure that accommodates straight LED pins. This eliminates the need for manual bending operations while maintaining proper LED positioning and electrical connection.
2Adaptability or versatility
If different bending tools are used for different connector structures, then LEDs can be adapted to various connector types, but the cost increases and automatic production becomes difficult
Solution Approach 1:
The patent designs a universal pin receiving structure in the housing that can accommodate LED pins for different connector types without requiring different bending tools. The housing structure itself provides the adaptability, allowing the same manufacturing process to be used across various connector configurations and enabling automatic production.
3Manufacturing precision
If LED pins are bent manually, then the LED can be positioned correctly, but the quality becomes unstable with pin breakage and poor contact
Solution Approach 1:
Instead of forcing the LED pins to conform to the connector structure through bending, the connector housing is designed with a pin receiving structure that conforms to the straight pins. This eliminates mechanical stress and damage to the pins during installation, ensuring stable quality without compromising positioning accuracy.
4Ease of operation
If special bending tools and manual operations are used, then the LED can be installed, but the production efficiency is low
Solution Approach 1:
The patent eliminates the need for manual bending operations by designing the housing to accommodate straight pins. This allows LEDs to be installed directly through automated placement machines, dramatically improving production efficiency while maintaining ease of installation through the user-friendly pin receiving structure.
Data Source
AI summary
The disclosure provides an electrical connector and a communication device. The electrical connector includes an insulator, on which at least one docking socket and at least one module socket are provided; a housing provided outside the insulator; a plug-in module provided on the insulator; and a signal display unit, which comprises a signal display circuit board, at least one SMD (surface-mounted-device) LED electrically coupled to the signal display circuit board, and at least two connection terminals electrically coupled to the signal display circuit board used to transmit signal of the signal display unit.