Electrical Connector Connecting Module Assembly
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Solution Overview
Problem
Existing electrical connectors face challenges in accurately mounting first and second contacts to a printed circuit board, leading to premature wear and increased maintenance costs due to rubbing during assembly.
Innovation Solution
An electrical connector design featuring a connecting module with a base, first pins, and a contacting subassembly that includes an inserting member and second pins, facilitating easy assembly by engaging the contacting subassembly with the base to avoid damage and ensure accurate alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If first and second contacts are mounted directly to the printed circuit board, then the assembly process becomes complex and time-consuming, but the contacts are prone to rubbing and premature wear during assembly
Solution Approach 1:
The connecting module is divided into a base and a contacting subassembly. The base is pre-assembled with first contacts, while the contacting subassembly contains second contacts that are inserted into the base during a separate step. This segmentation allows independent assembly of each component, improving overall assembly efficiency while protecting the contacts from damage during the process.
Solution Approach 2:
The first contacts are pre-assembled onto the base in advance, creating a pre-assembled base component. This preliminary action allows the contacts to be properly positioned and secured before the final assembly step, reducing the risk of rubbing and damage during the main assembly process while maintaining high productivity.
2Manufacturing precision
If first and second contacts are retained to a base of a connecting module, then the structure becomes more complex, but the assembly accuracy requirements increase leading to rubbing and wear
Solution Approach 1:
The connecting module structure is segmented into a base and a contacting subassembly. This segmentation simplifies the overall structure by allowing each component to be assembled independently with lower precision requirements, while the final insertion of the subassembly into the base provides the necessary alignment and positioning.
Solution Approach 2:
The base acts as an intermediary component between the printed circuit board and the contacting subassembly. It provides a stable mounting platform for the first contacts and a receptacle for the second contacts, simplifying the overall assembly process while maintaining the necessary structural integrity and electrical connectivity.
3Loss of time
If first and second contacts are assembled in a line through channels, then the assembly process is time-consuming, but the contacts are susceptible to rubbing and damage
Solution Approach 1:
The assembly process is segmented into two distinct steps: first, assembling the first contacts to the base; second, inserting the contacting subassembly with the second contacts into the base. This segmentation eliminates the need to assemble all contacts in a single time-consuming operation through channels, reducing both assembly time and the risk of rubbing and damage.
Solution Approach 2:
The first contacts are assembled to the base in advance as a preliminary step. This allows the base to be prepared beforehand with the first contacts properly positioned, and then the contacting subassembly is simply inserted into the base during the final assembly step, significantly reducing the overall assembly time and minimizing contact exposure to rubbing and damage.
Data Source
AI summary
An electrical connector (100) includes an insulative element (1) and an electrical unit (2) mounted to the insluative element. The electrical unit includes a housing (21), a terminal module (23) assembled to the housing, at least a daughter board (25) mounted to a side portion of the housing, and a connecting module (27). The connecting module has a base (271), a number of first pins (273) assembled to the base and extending through the daughter board, and at least a contacting subassembly (272) mounted to the base and having a number of second pins (277) connected to the daughter board.