Angled Electrical Header Connectors with One-Piece Housing
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Solution Overview
Problem
Conventional right-angle electrical headers are large due to externally pre-assembled terminals, leading to increased costs and reduced reliability, and lack adequate insulation, making them unsuitable for space-constrained applications and high-vibration environments.
Innovation Solution
A one-piece, integrally formed housing with internally oriented right-angle electrical terminals and insulators, ensuring robust connections and improved insulation within the housing, reducing packaging size and eliminating the need for multi-piece assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional right-angle electrical headers use externally pre-assembled terminals, then the electrical connection can be established, but the housing size becomes relatively large and the manufacturing cost increases
Solution Approach 1:
The patent merges the terminal assembly process with the housing manufacturing process by integrating terminals into the housing during injection molding. This eliminates the need for separate external assembly operations, reduces the overall housing size required to accommodate pre-assembled terminals, and lowers manufacturing costs through process integration and elimination of additional sealing requirements.
2Reliability
If conventional right-angle electrical headers use externally pre-assembled terminals, then the electrical connection can be established, but the reliability is reduced due to assembly and sealing requirements
Solution Approach 1:
The patent combines multiple functions (housing structure, terminal mounting, electrical insulation, and sealing) into a single integrally molded component. This eliminates the need for separate assembly steps and sealing operations, thereby improving reliability by removing potential failure points associated with multi-piece assemblies while reducing device complexity through functional integration.
3Volume of moving object
If conventional right-angle electrical headers are designed to accommodate externally attached terminals, then the electrical connection is established, but the packaging size increases
Solution Approach 1:
The patent integrates terminals directly into the housing structure during the molding process, allowing for a more compact packaging size. This integration enables the connector to better adapt to space-constrained applications while maintaining electrical functionality, thereby improving application flexibility without compromising the electrical connection capability.
4Reliability
If conventional right-angle electrical headers use external terminal assembly, then the electrical connection can be made, but the insulation protection between terminals and housing is inadequate
Solution Approach 1:
The patent integrates electrical insulation features directly into the housing structure through the injection molding process. The housing material itself provides electrical insulation between the terminals and the housing exterior, eliminating the need for separate insulation components and providing more reliable protection against short circuits in high-vibration environments.
Data Source
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AI summary
Angled electrical header connectors (10) comprise a housing (12) having a first terminal port (18) and a second terminal port (20) that may be at right angles relative to one another. A first electrical terminal (14) and first electrical terminal insulator (26) is disposed in the first terminal port (18), and a second electrical terminal (16) and second electrical terminal insulator (42) is disposed in the second electrical port (20). In an embodiment the housing is a one-piece construction and an opening (62) exists within the housing between the first electrical terminal port (18) and the second electrical terminal port (20). A mechanical and electrical attachment between the first electrical terminal (14) and the second electrical terminal (16) is made in situ within the housing.