Two-Piece Electrical Connector Carrier for Stable Pin Terminal Assembly
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Solution Overview
Problem
Existing electrical connectors with one-piece insulating carriers are complex and costly to assemble, especially when using eye-of-the-needle structure pin terminals, which require additional circuit boards and crimping processes.
Innovation Solution
The electrical connector features a two-piece housing insulating carrier, where intermediate terminals are held in one housing piece and pin terminals in the other, simplifying assembly and reducing costs by using conventional molds and dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a one-piece insulating carrier is used, then the structure is simple, but it cannot stably combine with eye-of-the-needle structure pin terminals
Solution Approach 1:
The insulating carrier is divided into two separate housing pieces: a first housing piece that holds the intermediate terminals and a second housing piece that holds the pin terminals. This segmentation allows each housing piece to be optimized for its specific function, enabling stable combination with eye-of-the-needle structure pin terminals while maintaining structural simplicity through modular design.
2Ease of manufacture
If additional circuit boards are added to assemble eye-of-the-needle structure pin terminals, then the terminal combination is achieved, but the process becomes complicated and cost increases
Solution Approach 1:
The patent merges the functions of multiple components into the two-piece housing structure. The first and second housing pieces directly hold the intermediate and pin terminals respectively, eliminating the need for separate circuit boards. This consolidation simplifies the assembly process and reduces manufacturing complexity while maintaining the ability to assemble eye-of-the-needle structure pin terminals.
3Ease of manufacture
If conventional molds and dies are used, then the equipment investment is low, but the assembly of eye-of-the-needle structure pin terminals is difficult
Solution Approach 1:
The patent applies local quality by designing the second housing piece with specific structural features optimized for holding eye-of-the-needle structure pin terminals. The housing pieces are formed with appropriate cavities, positioning features, and fixing structures that provide stable combination for the terminals. This localized optimization allows conventional molds and dies to be used while achieving reliable terminal assembly.
Data Source
AI summary
An electrical connector for mounting on an external circuit board includes: an insulating body; a terminal module assembled on the insulating body and including a plurality of mating terminals, an insulating carrier with an accommodating cavity, plural intermediate terminals fixed on one side of the insulating carrier and electrically connected to the mating terminals, plural pin terminals fixed on the other side of the insulating carrier, and a magnetic module accommodated in the accommodating cavity and electrically connected to the intermediate terminals and the pin terminals, wherein the insulating carrier is a two-piece housing, the intermediate terminals are held in one housing piece, and the pin terminals are held in the other housing piece.