Electrical Connector Contact Modules with Insulative Blocks

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Solution Overview

Problem

Conventional methods for manufacturing electrical connectors damage the mechanical and electrical performance, especially in miniature connectors, due to the wear and tear of contacts with the side walls of the passageways, leading to adverse effects on signal transmission.

Innovation Solution

An electrical connector design featuring an insulative housing with a tongue plate and through holes, where contact modules are insert molded and retained within the housing, and a metal shell encloses the assembly, forming a receiving space to prevent contact wear and enhance signal transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If contacts are inserted into passageways using conventional forcing method, then contacts can be assembled into the insulative housing, but the contacts wear away surfaces of the side walls of the contact passageways

Engineering Contradiction:

Improvecontact assembly methodVSAvoidsignal transmission quality

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent introduces an insulative block as an intermediary component that holds the contacts in a stacked arrangement. This insulative block is then inserted as a single unit into the cavity of the insulative housing, rather than forcing individual contacts into separate passageways. The insulative block acts as a mediator that facilitates the assembly process while protecting the contact surfaces from direct contact with the side walls of the passageways, thereby preventing wear and maintaining signal transmission quality.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If contacts are forced into the housing, then assembly can be completed, but the mechanical and electrical performance of the electrical connector is damaged

Engineering Contradiction:

Improveassembly efficiencyVSAvoidmechanical performance

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The patent merges multiple contacts into a single stacked assembly held by an insulative block. This combined assembly is then inserted into the housing as one unit, eliminating the need to force individual contacts into separate passageways. The merging of contacts into a unified structure maintains mechanical integrity and electrical performance while simplifying the assembly process and improving productivity.

Inventive Principle:

Principle #5Merging (Combining)

3Volume of moving object

If contacts are arranged closely in miniature electrical connector, then miniaturization is achieved, but the side walls of the contact passageways become weak and susceptible to wear

Engineering Contradiction:

Improveconnector sizeVSAvoidcontact wear

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The insulative block serves as a protective intermediary that prevents direct contact between the contact surfaces and the weakened side walls of the passageways. In miniature connectors where contacts are closely arranged and side walls are inherently weaker, this intermediary structure is crucial for preventing wear while maintaining the compact design and achieving miniaturization.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution effectively prevents contact wear and enhances signal transmission by securely retaining contact modules within the insulative housing, maintaining the mechanical and electrical performance of the connector.

Implementation Method 1

the insulative blocks each defines a front portion retained in the cavity of the insulative housing for the contact modules being retained with the insulative housing reliably

Methodology Applied

Scientific EffectMechanical retention: Mechanical Fastener

Implementation Method 2

a metal shell enclosing the insulative housing and the contact modules, a receiving space being formed between the shell and the tongue plate

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Implementation Method 3

a row of contacts being insert molded in the insulative housing

Methodology Applied

Scientific EffectInsert molding:

Data Source

PatentUS8011969B2Electrical connector with contact modules

Publication Date: 2011.09.06 HON HAI PRECISION INDUSTRY CO LTD

AI summary

An electrical connector includes an insulative housing including a base portion and mating tongue plate protruding forwardly from the base portion; two contact modules being retained with each other and each including an insulative block, and a row of contacts being insert molded in the insulative housing, and a metal shell enclosing the insulative housing and the contact modules. A receiving space is formed between the shell and the tongue plate. The insulative blocks each defines a front portion inserted in the cavity of the insulative housing for the contact modules being retained with the insulative housing reliably.