Asymmetric Guide Surface for Electrical Connector Pin Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connector assemblies face issues with pins being inserted incorrectly, leading to damage of terminals or insulating bodies due to symmetrically provided chamfers shortening the guiding path, resulting in improper alignment and contact.
Innovation Solution
The electrical connector assembly features a plug with a guide surface passing through the vertical center line of the insertion portion, accompanied by contact regions higher than the guide surface, and a socket with clamping portions that ensure accurate alignment and contact, prolonging the guiding path for smooth insertion and preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two symmetrical chamfers are provided on the insertion portion, then the structure is simple and easy to manufacture, but the guiding path is shortened causing pins to be inserted away from the correct position
Solution Approach 1:
The patent replaces the traditional symmetrical chamfer structure with an asymmetric guide surface design. The guide surface extends along the insertion portion at an angle, creating an asymmetric guiding path that lengthens the insertion trajectory. This asymmetric structure ensures pins are guided to the correct insertion position while maintaining manufacturing feasibility through standardized forming processes.
2Productivity
If the guiding path is shortened by symmetrical chamfers, then the insertion process is faster, but pins may press terminals or insulating body downward causing damage
Solution Approach 1:
The guide surface performs preliminary alignment action during the insertion process. By extending the guiding path along the insertion portion, the guide surface pre-positions the pin at the correct angle and location before contact with the terminal. This preliminary guiding action prevents lateral misalignment that would cause downward pressing and damage to terminals or the insulating body.
3Device complexity
If symmetrical chamfers are used, then the structure is simpler, but the pins cannot be accurately aligned with the terminals
Solution Approach 1:
The patent employs asymmetric guide surfaces that extend at specific angles along the insertion portion. This asymmetric configuration creates a unique guiding trajectory that precisely aligns pins with terminals. The guide surface maintains structural simplicity while achieving high alignment precision through its angular geometry and extended path, avoiding the need for complex multi-component alignment mechanisms.
Data Source
AI summary
An electrical connector assembly includes a plug, having a body and multiple pins positioned on the body, and a socket connector including an insulating body. Each pin has an insertion portion extending downward out of the body. The insertion portion has a guide surface, and two contact regions located above the guide surface. The guide surface passes through a vertical center line of the insertion portion. Multiple accommodating holes run through the insulating body vertically. Multiple terminals are respectively accommodated in the accommodating holes. Each terminal is provided with two clamping portions. The guide surfaces guide the pins to be inserted downward into the accommodating holes. When each pin is inserted downward to a final position, the insertion portion is located between the two clamping portions, the two clamping portions are correspondingly in contact with the two contact regions, and the guide surface is located below the two clamping portions.