Electrical Connector Base Element Cutout for Terminal Module Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors with symmetrically arranged base parts and embedded terminals are complicated to manufacture and unstable due to the design of grooves for connecting pin sets, leading to assembly challenges.
Innovation Solution
An electrical connector design featuring a base element with opposite contacting portions and a cutout that engages with a terminal module's insulative insert, providing a stable and easy assembly through interference fit, along with daughter boards and a spacer for secure mounting of terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two grooves are defined at the front sides of the left and right base parts to assemble the two connecting pin sets, then the connecting pin sets can be coupled, but the manufacture of the electrical connector becomes complicated and the structure becomes unstable
Solution Approach 1:
The patent merges the functions of the left and right base parts into a single integrated base element. The base element includes a single cutout that simultaneously receives both connecting pin sets, eliminating the need for separate grooves in multiple base parts. This integration simplifies the manufacturing process while maintaining structural stability through the unified design.
Solution Approach 2:
The patent extracts the connecting pin sets from the base element structure, allowing them to be independently positioned and secured within the cutout. This separation enables the base element to provide overall structural support while the cutout specifically accommodates the pin sets, simplifying manufacturing and improving assembly ease.
2Reliability
If the terminal module is mounted into the cutout with interference fit between the passage and inner edge, then the mounting becomes firm and stable, but the assembly process requires precise alignment
Solution Approach 1:
The base element is pre-formed with the cutout and the insulative insert is pre-formed with the passage, so that when assembled, the interference fit is automatically achieved without requiring additional fastening operations. The geometry of the cutout and passage are designed to create the interference fit upon insertion, ensuring firm mounting while maintaining assembly simplicity.
Solution Approach 2:
The interference fit between the passage and inner edge of the cutout creates a self-securing mechanism. Once the terminal module is inserted into the cutout, the interference fit automatically locks the components together without requiring external fasteners or additional assembly steps, ensuring both firm mounting and ease of operation.
Data Source
AI summary
An electrical connector (200) for engaging with a mating plug includes a terminal module (400) having an insulative insert (401) and rows of terminals (4) mounted to the insulative insert, a base element (300) and a daughter board (600) attached to a side face of the base element. The base element has a pair of opposite contacting portions (301) disposed on a front section thereof and a cutout (10) defined between the pair of contacting portions. The cutout is configured to cooperate with the terminal module with an inner edge (31) engaging to a corresponding passage (81) defined on a rear face of the insulative insert.