LED Positioning in Modular Jacks via Crank-Shaped Legs
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Solution Overview
Problem
Existing electrical connectors with integrated LEDs have complex positioning structures that can lead to damage during assembly and do not meet miniaturization requirements, with the insulative latch being prone to breakage.
Innovation Solution
An electrical connector design featuring an insulative housing with LEDs positioned at corners, using L-shaped and crank-shaped contact legs that are securely held by protruding tubers, reducing complexity and risk of damage during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the LED device is retained by an insulative latch in a through-hole, then the LED can be positioned in the electrical connector, but the structure becomes complex and the latch is prone to breakage during assembly
Solution Approach 1:
The patent removes the insulative latch component entirely from the positioning structure. Instead of using a separate latch element that can break, the design integrates the positioning function directly into the housing structure through the crank-shaped contact leg configuration, eliminating the weak latch component.
Solution Approach 2:
The positioning function is merged with the contact leg structure itself. The crank-shaped contact leg integrates both the electrical contact function and the mechanical positioning function into a single component, eliminating the need for separate positioning elements like latches or step portions.
2Reliability
If the LED device includes a light body with step portion blocking the insulative latch, then the LED can be positioned, but the structure becomes more complicated
Solution Approach 1:
The patent eliminates the step portion feature from the light body design. The positioning is achieved entirely through the crank-shaped contact leg geometry, removing the need for additional structural features like step portions that complicate the assembly process.
Solution Approach 2:
The crank-shaped contact leg is self-positioning through its own geometric configuration. The curved path of the contact leg automatically guides and positions the LED during assembly without requiring additional positioning features or complex interactions with latches.
3Reliability
If the insulative latch is used to lock the LED device, then the LED can be secured, but the latch can be easily broken during assembly
Solution Approach 1:
The patent completely removes the insulative latch from the design, eliminating the component that is prone to breakage. The retention function is achieved through the geometric constraint of the crank-shaped contact leg fitting within the housing structure.
Solution Approach 2:
The design uses a simple, robust contact leg structure that is inherently stronger and more durable than the previous latch mechanism. The crank-shaped geometry provides inherent mechanical strength while maintaining the retention function.
Data Source
AI summary
An electrical connector (100) includes an insulative housing (1) with a mating space (13), a plurality of contacts (21) disposed in the insulative housing (1) with a mating portion (211) protruding into the mating space (13), a metallic shell (4) covering the insulative housing and a pair of LEDs (3) disposed at a corner of the insulative housing (1) and capable of emitting light indicating proper function thereof. Each LED (3) includes a pair of contact legs (31, 32), one of the contact legs (32) has a crank-shaped portion (320) sandwiched between a pair of protruding tubers (125a, 125b) formed by the insulative housing (1).