Electrical Connector with Differential Soldering Widths
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Solution Overview
Problem
High-density electrical connectors face challenges in miniaturization, where smaller distances between contacts increase production costs due to the need for larger power contacts and separate manufacturing processes, leading to inefficiencies in signal transfer and increased costs.
Innovation Solution
An electrical connector design featuring two types of conductive contacts with the same distance between adjacent soldering portions, where the second type has a wider soldering portion to improve welding efficiency and allow simultaneous production and assembly, maintaining consistent spacing and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If power contacts are made larger to transfer larger current, then current transfer capability is improved, but connector size increases
Solution Approach 1:
The patent applies local quality by differentiating the soldering portion width based on contact type. Power contacts have wider soldering portions to accommodate higher current density and welding requirements, while signal contacts maintain narrower soldering portions. This localized differentiation optimizes current transfer capability where needed without increasing the overall connector dimensions.
2Power
If power contacts are produced separately from signal contacts, then current transfer optimization is achieved, but production cost increases
Solution Approach 1:
The patent merges the production process of power contacts and signal contacts into a single simultaneous manufacturing operation. Both contact types are produced in the same mold cavity during one injection molding cycle, eliminating the need for separate production processes. This reduces manufacturing complexity and cost while maintaining the optimized current transfer capability of power contacts.
Solution Approach 2:
The patent creates a universal mold that can produce both power contacts and signal contacts in a single operation. The mold design incorporates multiple cavities or inserts that form different contact types simultaneously, making the manufacturing system multi-functional and eliminating the need for separate dedicated production lines for each contact type.
3Volume of moving object
If distance between adjacent contacts is reduced for miniaturization, then connector density is improved, but welding reliability deteriorates
Solution Approach 1:
The patent applies local quality by providing wider soldering portions specifically at the contact points where welding occurs, while maintaining narrow spacing between adjacent contacts in the array. This localized width enhancement at critical welding zones ensures reliable solder joint formation even when contacts are densely packed, resolving the conflict between miniaturization and welding reliability.
Data Source
AI summary
An electrical connector includes an insulating housing (1) defining a first direction and a plurality of conductive contacts (20) arrayed in the housing along the first direction. The contacts are divided into a first type and a second type and each includes a soldering portion extending out the insulating housing. The soldering portion of the second type is wider than that of the first type and distances between every adjacent soldering portions of the first and second type are the same.