Electrical Connector Terminal Layout With Cuttable Material Bridges
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Solution Overview
Problem
Conventional electrical connector manufacturing processes require separate development of stamping dies and molds for upper and lower terminal sets, leading to increased costs and longer development and manufacturing times.
Innovation Solution
The electrical connector design features a staggered upper and lower layer structure for first and second terminal sets, with shared material bridges that are cut simultaneously using a preset cutting tool during insert molding, eliminating electrical connections and reducing mold development time by half.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate stamping dies are used for upper and lower terminal sets, then each terminal set can be manufactured independently, but the die development cost and development time increase
Solution Approach 1:
The patent merges the manufacturing of upper and lower terminal sets into a single stamping die. The die includes upper and lower die bodies that can simultaneously form both terminal sets from a single conductive sheet, eliminating the need for separate stamping dies for each terminal set and reducing die development time and cost.
Solution Approach 2:
The patent segments the terminal sets spatially within a single stamping die by positioning upper and lower die bodies at different levels. The upper terminal set and lower terminal set are formed in different regions of the conductive sheet simultaneously, allowing independent manufacturing within the unified die structure.
2Manufacturing precision
If separate molds are used for insert molding upper and lower terminal sets, then each terminal set can be embedded independently, but the assembly cost and manufacturing time increase
Solution Approach 1:
The patent combines the insert molding process for upper and lower terminal sets into a single mold operation. The mold includes cavities for both terminal sets, allowing simultaneous embedding of both terminal sets into the insulating base in one manufacturing step, thereby reducing assembly cost and manufacturing time.
Solution Approach 2:
The patent segments the mold cavities into upper and lower regions corresponding to the respective terminal sets. This spatial segmentation allows each terminal set to be independently positioned and embedded while maintaining the ability to perform both operations simultaneously in a single mold cycle.
3Reliability
If material bridges connect terminals in upper and lower terminal sets, then electrical connections are formed, but unwanted electrical connections increase complexity
Solution Approach 1:
The patent extracts and removes the material bridges that connect the upper and lower terminal sets after the terminals have been formed and embedded. By taking out these connecting material bridges, the patent prevents unwanted electrical connections between the terminal sets while maintaining the structural integrity needed for the manufacturing process.
Data Source
AI summary
An electrical connector includes a first terminal set including first terminals and first material bridges forming electrical connections between the first terminals, a second terminal set including second terminals and second material bridges forming electrical connections between the second terminals, and an insulating body formed on the first and second terminal sets by insert molding. The insulating body has a top surface thereof provided with first and second punching holes that expose the first and second material bridges for allowing a preset cutting tool to be used to cut the first and second material bridges and carry out waste removal, so that the first terminals and the second terminals are independent without producing electrical connections.