Coaxial Connector Terminals with Insert Molded Support
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Solution Overview
Problem
Existing connectors face challenges in minimizing size while ensuring terminal strength and easy connectability, as smaller sizes make it difficult to support terminals and align markings, leading to potential damage and connection difficulties.
Innovation Solution
The connector device employs a configuration with resin-molded supporting parts and cylindrical contact pieces to firmly support and align terminals, utilizing insert molding to enhance strength and alignment, and coaxial disposition to facilitate easy connection and prevent resin flow issues during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the size of connector is decreased, then the size of connector housing and terminals become smaller, but it becomes difficult to construct a structure for firmly supporting the terminals inside the connector housing
Solution Approach 1:
The patent merges the terminal support structure with the connector housing by using a single resin molded body that integrates both functions. The housing itself forms the support structure through integrated ribs and positioning features, eliminating the need for separate support components and maintaining strength while reducing overall size.
Solution Approach 2:
The patent uses resin molded materials that combine structural support capabilities with housing functions. The resin material allows for complex integrated geometries that provide both enclosure and terminal support in a single component, achieving firm terminal support in a compact form factor.
2Volume of moving object
If the size of connector is decreased, then the diameter of each terminal becomes small, but it becomes difficult to secure the strength of terminals
Solution Approach 1:
The patent applies local quality by concentrating support structures specifically at terminal locations within the housing. The resin molded housing includes localized ribs, recesses, and positioning features that provide enhanced support exactly where terminals are inserted, while keeping other areas of the housing minimal in size.
Solution Approach 2:
The patent incorporates preliminary action by pre-forming the terminal support structures as integral parts of the housing during the molding process. The support features are created in advance as part of the housing geometry, ensuring terminals are firmly supported from the moment of insertion without requiring additional assembly steps.
3Volume of moving object
If the size of connector is decreased, then the size of marks on outer circumferential face becomes smaller, but it becomes difficult to recognize the marks for alignment
Solution Approach 1:
The patent uses asymmetry in the alignment mark design where one connector (the plug) features a protruding rib and the other (the receptacle) has a corresponding groove. This asymmetric mechanical feature provides unambiguous orientation guidance without relying solely on small visual marks, solving the recognition difficulty in compact connectors.
Solution Approach 2:
The patent introduces mechanical alignment features (ribs and grooves) as intermediaries between the connectors. These features physically guide the connectors into proper alignment during insertion, supplementing the visual marks and providing tactile feedback that aids alignment even when marks are small and difficult to see.
4Volume of moving object
If the size of connector is decreased, then it is not easy to finely turn the connector in circumferential direction by picking it with fingers, but alignment of rib and groove becomes necessary for proper connection
Solution Approach 1:
The patent employs asymmetry by providing a rib-protrusion on one connector and a corresponding groove on the other, creating a unique orientation that guides proper alignment. This asymmetric mechanical interface naturally directs the connectors into the correct relative position during insertion, reducing the need for manual fine-adjustment.
Solution Approach 2:
The patent implements self-service alignment where the rib and groove features automatically guide the connectors into proper alignment during the insertion process itself. The mechanical interfitting features perform the alignment function without requiring separate manual positioning steps, making the connection process self-aligning.
Data Source
Figure 1~2
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Figure 5~6
AI summary
Contact pieces (13, 19, 25) of an inside terminal (12), an intermediate terminal (18) and an outside terminal (24) of a receptacle (11) of a connector device (1) are formed into a pin shape or cylindrical shape, and disposed coaxially. A supporting part (30) for supporting the inside terminal (12), the intermediate terminal (18) and the outside terminal (24) is produced by insert molding so as to enclose coupling parts of these terminals. Contact pieces (44, 50, 56) of an inside terminal (43), an intermediate terminal (49) and an outside terminal (55) of a plug (41) of the connector device (1) are formed into a cylindrical shape, and disposed coaxially. A supporting part (65) for supporting the inside terminal (43), the intermediate terminal (49) and the outside terminal (55) is produced by insert molding so as to enclose coupling parts of these terminals.