LED Connector Structure With Notched Base for Easier Rod Assembly
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Solution Overview
Problem
The existing electrical connectors with integrated light-emitting diodes face challenges in processing difficulty and increased manufacturing costs due to the need for long, bent metal conductive rods, which complicates assembly and reduces production efficiency.
Innovation Solution
An electrical connector structure with an insulating base featuring notches and engagement grooves for easy insertion of conductive rods, a top cover with locking hooks and compression structures to secure the rods, and a back cover for bending, facilitating convenient assembly and secure fixation of light-emitting diodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If light-emitting diodes are arranged in an upper part of the plastic housing, then the connector provides visual indications of signal status, but the metal conductive rods need to be longer and bent into inverted L shape, increasing processing difficulty and manufacturing costs
Solution Approach 1:
The patent inverts the conventional arrangement by placing the light-emitting diodes in the lower part of the housing instead of the upper part. This inversion allows the metal conductive rods to be shorter and eliminates the need for complex bending into inverted L shapes, directly resolving the manufacturing difficulty while preserving the visual indication function through proper positioning of the LED light-emitting surfaces.
2Ease of operation
If metal conductive rods are made longer and bent into inverted L shape, then soldering to circuit board is facilitated, but processing complexity and manufacturing costs increase
Solution Approach 1:
Instead of bending the conductive rods into complex inverted L shapes to achieve proper soldering positioning, the patent inverts the LED arrangement to allow the rods to remain simpler in form. The shortened rods with modified positioning achieve the same soldering convenience through the inverted LED placement, reducing rod shape complexity while maintaining ease of soldering operation.
3Reliability
If conventional LED arrangement is used, then signal status indication is provided, but production efficiency is reduced due to cumbersome processing processes
Solution Approach 1:
The patent inverts the conventional LED arrangement from upper to lower positioning in the housing. This inversion simplifies the conductive rod requirements, eliminating lengthy bending operations and reducing processing steps. The simplified structure enables faster assembly and manufacturing while maintaining the essential signal status indication function, thereby improving production efficiency.
Data Source
AI summary
An electrical connector structure includes an insulating base, two light-emitting diodes, a top cover, and a back cover. A through slot extends through the insulating base. A top surface of the insulating base includes two engagement grooves and two notches. The engagement grooves communicate with the notches. Each light-emitting diode includes a light-emitting body and two conductive rods. The light-emitting bodies are embedded in the engagement grooves. Each conductive rod includes a horizontal section and a vertical section bent vertically. Each horizontal section is received in each notch. The top cover is connected to the insulating base to cover the two light-emitting diodes. The back cover is pivotally connected to the insulating base and covers another end of the through slot. The back cover includes through holes for insertion of the vertical sections, allowing for convenient assembly of the conductive rods into the insulating base through the notches.