LED Connector Module With Integrated Header-Plug Wiring Simplification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The complexity of wiring harnesses and increased manufacturing costs in refrigerators due to the use of numerous wire-to-wire connectors for connecting door switches and LED modules to mainboards.
Innovation Solution
A light-emitting diode (LED) connector module comprising a header housing and a plug housing with a tab terminal and receptacle terminal configuration, allowing for a direct electrical connection between the LED module and mainboard without the need for additional wire connections, thereby simplifying the wiring structure and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire-to-wire connectors are used to connect door switch and LED module to mainboard, then electrical connection is achieved, but wiring harness complexity increases and manufacturing costs rise
Solution Approach 1:
The patent combines the door switch and LED module into a single integrated connector assembly that connects to the mainboard through one unified connector. This merging eliminates the need for separate wire-to-wire connectors for each component, thereby reducing wiring harness complexity while maintaining reliable electrical connections for both the door switch signal and LED module power.
Solution Approach 2:
The connector assembly is designed to perform multiple functions simultaneously: it provides electrical connection for the door switch, power supply for the LED module, and integrated sealing. This multi-functional design replaces what would traditionally require multiple separate connectors and wiring steps, simplifying the overall wiring harness structure.
2Reliability
If wire-to-wire connectors are used for connecting components, then electrical connection is established, but manufacturing process time increases
Solution Approach 1:
The door switch and LED module are pre-assembled into an integrated connector assembly before final installation to the mainboard. This preliminary integration of multiple components into a single unit reduces the number of assembly steps required during manufacturing, as the pre-assembled unit can be installed in one operation rather than requiring separate connection steps for each component.
3Reliability
If multiple wire-to-wire connectors are used, then all electrical connections are made, but overall costs increase
Solution Approach 1:
The patent merges multiple separate connectors into a single integrated connector assembly, reducing the total number of connector components required. This consolidation lowers material costs, reduces inventory requirements, and simplifies the supply chain, thereby reducing overall manufacturing costs while maintaining all necessary electrical connections.
Data Source
AI summary
A light-emitting diode (LED) connector module includes a header housing and a plug housing removably attached to the header housing. The header housing is installed on an LED module. The header housing has a tab terminal protruding from a coupling surface. The plug housing has a receptacle terminal and a tab terminal coupling portion. The tab terminal is inserted in the tab terminal coupling portion in contact with the receptacle terminal.