Lighted Electrical Connector Housing with Clamshell LED
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Solution Overview
Problem
Existing electrical connector housings lack a field-installable lighting solution that confirms connection integrity without altering the connector's configuration or interfering with its mounting on an electrical panel.
Innovation Solution
A field-installable coupling cover with a clamshell configuration, featuring an insulation piercing connector and LED lighting assembly that indicates power flow through the connector, allowing for color coding and visibility of illumination through a translucent housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lighting components are added to the connector housing, then connection confirmation capability is improved, but device complexity increases
Solution Approach 1:
The patent combines the lighting assembly with the connector housing by integrating the light source, housing, and mounting structure into a single unified component. The light source is positioned within the housing and secured through mounting features integrated into the housing structure, eliminating the need for separate lighting components and reducing overall device complexity while maintaining connection confirmation capability
Solution Approach 2:
The connector housing serves multiple functions: it provides structural support for the electrical contacts, houses and protects the light source, and integrates mounting features for securing the assembly. This multi-functionality reduces the need for additional separate components, resolving the contradiction between improved reliability through lighting and reduced device complexity
2Ease of operation
If lighting assembly is field installed on manufactured connector, then ease of installation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The housing is pre-formed with integrated mounting features during manufacturing, including recesses and attachment mechanisms that are built into the housing structure before field installation. This preliminary preparation of mounting features simplifies the field installation process while maintaining precise alignment requirements that are satisfied during the initial housing manufacturing process
Solution Approach 2:
The lighting assembly is designed as a separate field-installable component that can be attached to the manufactured connector housing. The housing itself is segmented into features that accommodate the light source independently, allowing the lighting assembly to be installed after the connector housing is manufactured, thereby improving ease of installation while managing precision requirements through modular design
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
Enables easy differentiation between connectors and confirms connection integrity by illuminating when power is present, ensuring proper connections without interfering with the connector's mounting on a panel.
Implementation Method 1
a light that is connected by an insulation piercing connector that when lit would indicate power through the couplings to the component
Implementation Method 2
The housing has a viewing window through which the illumination of the light bulb is visible. Alternatively, the housing has a translucent area through which the illumination of the light bulb is visible
Data Source
AI summary
A cover assembly for an electrical connector at the end of a sheathed cable containing several insulated wires. An insulation piercing clip couples light bulb leads to the wires. A translucent housing encloses the light bulb, said insulation piercing clip, the entire section of unsheathed insulated wires, a portion of the electrical connector and a portion of the sheathed cable. The cover assembly is illuminated by the light bulb when power flows through the electrical connector and may be color coded to indicate connector function.