Adapter Terminals for Electrical Connector Cable Assembly
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Solution Overview
Problem
The existing assembly process for electrical connectors and cable units is complex and time-consuming due to the need for soldering conductive terminals onto circuit boards to connect audio connectors to motherboards through cable units.
Innovation Solution
The introduction of adapter terminals that electrically connect conductive terminals of an electrical connector to cables of a cable unit, eliminating the need for soldering by using insert arms and gripping plates to secure the adapter terminals onto the conductive terminals and core wires, allowing for a more straightforward assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive terminals are soldered onto circuit board to connect audio connector to mother board through cable unit, then electrical connection is achieved, but assembling procedure becomes complicated and time-consuming
Solution Approach 1:
The patent introduces adapter terminals as intermediary components that connect conductive terminals to cable cores without requiring soldering to the circuit board. The adapter terminals serve as mediators that simplify the assembly process while maintaining reliable electrical connections, eliminating the complex soldering procedure described in the contradiction.
Solution Approach 2:
The patent segments the electrical connection system into distinct modular components: conductive terminals, adapter terminals, and cable cores. This segmentation allows each component to be assembled independently and connected through simple insertion rather than complex soldering, reducing assembly complexity while maintaining connection reliability.
2Reliability
If conductive terminals are soldered onto circuit board, then electrical connection is established, but assembling time increases
Solution Approach 1:
The adapter terminals are pre-assembled with cable cores before final installation. This preliminary preparation allows the main assembly process to proceed faster by eliminating on-site soldering operations, directly addressing the productivity issue while ensuring reliable electrical connections are already established before final assembly.
Solution Approach 2:
The patent replaces the thermal-mechanical soldering process with a purely mechanical insertion system using adapter terminals. This substitution eliminates the time-consuming soldering step while maintaining electrical connection reliability, directly improving assembly productivity.
3Ease of operation
If adapter terminals are used to connect conductive terminals to cables, then assembly convenience is enhanced, but device structure becomes more complex
Solution Approach 1:
The adapter terminals merge multiple functions into a single component: they provide electrical connection, mechanical support, and structural alignment between conductive terminals and cable cores. This merging simplifies the overall assembly process and improves ease of operation while the added structural elements are consolidated into integrated adapter components rather than separate parts.
Data Source
AI summary
An assembly includes an electrical connector, a cable unit, and adapter terminals. The electrical connector includes an insulator body and conductive terminals disposed at the insulator body. Each conductive terminal includes an insert arm positioned outside the insulator body. The cable unit includes a plug connector and cables connected to the plug connector. Each of the adapter terminals is connected to a core wire of a corresponding cable and is sleeved on the insert arm of a corresponding conductive terminal. Each adapter terminal is electrically connected between the core wire of the corresponding cable and the insert arm of the corresponding conductive terminal.