Electrical Connector Assembly Using Adapter Module for Staggered Terminals
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Solution Overview
Problem
The increasing speed of electrical connector transmission requires staggered terminals, leading to extra manufacturing costs and environmental waste due to the need for multiple terminal specifications and frequent mold redesigns to accommodate new motherboards.
Innovation Solution
An electrical connector assembly with an adapter module that uses terminals of a single specification, featuring a terminal fixing member with parallel rows of holes for insert molding, allowing uniform alignment and reduced waste, and enabling compatibility with various motherboards through adjustable terminal arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If terminals are staggered to prevent electromagnetic interference, then transmission speed is improved, but manufacturing cost increases due to multiple terminal specifications
Solution Approach 1:
The connector is divided into a housing portion and a terminal portion that can be independently molded and assembled. The terminal portion is then injected into the housing portion, allowing the terminals to be staggered for high-speed transmission while using a single standardized terminal design for mass production, thus resolving the contradiction between transmission speed and manufacturing cost.
Solution Approach 2:
The terminal portion is nested within the housing portion through a two-shot molding process where the terminal portion is injected into the previously formed housing portion. This nesting structure allows the terminals to be positioned in a staggered arrangement for electromagnetic interference prevention while maintaining a compact, integrated connector design that simplifies manufacturing.
2Adaptability or versatility
If multiple terminal specifications are produced for different motherboards, then compatibility is improved, but production cost increases due to frequent mold redesigns
Solution Approach 1:
The terminal portion is designed with a flexible arrangement that can be adapted to different motherboard layouts through the two-shot molding process. The terminals can be positioned in various staggered patterns within the housing to accommodate different soldering point arrangements on motherboards, providing adaptability without requiring complete mold redesigns.
Solution Approach 2:
The connector design uses a universal housing portion that can accommodate multiple terminal arrangements. By maintaining a standardized terminal portion design and only adjusting the positioning within the housing, the connector can be adapted to work with different motherboard specifications, achieving multi-functionality without frequent mold redesigns.
3Strength
If terminals are punched out to create bifurcated structures, then fixing capability is improved, but metal waste increases causing environmental pollution
Solution Approach 1:
The terminal structure is changed from a punched-out bifurcated design to an integrated structure formed through the two-shot molding process. The terminal portion is molded as a single piece with extended ends that naturally form the fixing structure, eliminating the need for punching operations and the associated metal waste while maintaining the necessary fixing capability.
Solution Approach 2:
The connector utilizes a composite structure where the housing portion and terminal portion are made of different materials optimized for their respective functions. The terminal portion is molded from conductive material with integrated fixing features, eliminating waste from traditional punching processes while the housing provides structural support, together achieving both fixing capability and environmental sustainability.
Data Source
AI summary
An electrical connector assembly includes first and second connectors and an adapter module having an assembler member for assembling the first and second connectors together. The first connector has a terminal confining plate for confining the terminals therethrough. Each terminal has a contact section, a distributing section and an intermediate section interconnecting the contact and distributing sections. The adapter module further includes a one-piece terminal fixing member disposed within the assembler member for coupling to the terminal confining plate. The terminal fixing member is formed with first and second rows of terminal holes spaced apart in parallel manner, wherein the intermediate sections of the terminals are embedded within the first and second rows of terminal holes via insert molding process such that the contact and distributing sections of the terminals extend outward from two opposite sides of the terminal fixing member.