Electrical Connector with Embedded Contacts and Insulating Substrates
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Solution Overview
Problem
Conventional electrical connectors for chip modules and circuit boards are costly to manufacture due to the need for separate plastic and metal molds, generate significant waste, and require labor-intensive assembly, with thin insulating bodies prone to breakage as devices become thinner.
Innovation Solution
The electrical connector design features cut insulating substrates with tongues and through-holes, where contacts are adhered between the substrates, eliminating the need for molds and manual assembly, and utilizing soft materials to reduce thickness and manufacturing costs while allowing for elastic deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate plastic and metal molds are used to manufacture insulating body and contacts, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the insulating body and contacts into a single integrated structure where contacts are embedded directly within the insulating body. This eliminates the need for separate plastic and metal molds, reducing manufacturing cost while maintaining precision through a unified manufacturing process.
Solution Approach 2:
The insulating body serves multiple functions: it provides electrical insulation, structural support, and direct integration of contacts. This multi-functionality eliminates the need for separate components and assembly processes, reducing overall manufacturing complexity and cost.
2Manufacturing precision
If contacts are manufactured separately and plugged into insulating body, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The contacts are embedded within the insulating body as a single integrated component rather than being assembled separately. This eliminates the time-consuming plugging process while maintaining precise positioning through the integrated design.
Solution Approach 2:
The contacts are pre-positioned and embedded within the insulating body during the manufacturing process itself, rather than being assembled later. This preliminary integration eliminates subsequent assembly steps and improves overall productivity.
3Length of stationary object
If insulating body is made thinner to reduce connector height, then device thickness is reduced, but strength decreases
Solution Approach 1:
The insulating body incorporates conductive adhesive material that provides both electrical connection and structural reinforcement. This composite structure allows the insulating body to be thinner while maintaining strength through the reinforcing adhesive material.
Solution Approach 2:
The insulating body features an asymmetric structure with a first surface and second surface where the contact embedding creates localized reinforcement. This asymmetric design allows thinning in certain areas while maintaining strength where contacts are embedded.
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
This design reduces manufacturing costs, minimizes material waste, prevents contact breakage, and allows for a lower profile connector with enhanced durability and assembly efficiency, enabling thinner, more robust connectors for thinner devices.
Implementation Method 1
a plurality of contacts adhered between the first tongues and the second tongues
Data Source
AI summary
An electrical connector includes at least one first insulating substrate having first tongues, at least one second insulating substrate having second tongues, and a plurality of contacts. One end of the first tongue connects to the first insulating substrate. There are through-holes in the first insulating substrate for the second tongues to pass through. One end of the second tongue connects to the second insulating substrate. With respect to the upper surface of the first insulating substrate, the other end of the first insulating substrates defines a first height difference, the other end of the second tongue defines a second height difference and the upper-most portion of the contact defines a third height difference which is larger than the first and second height differences. There are holes in the second insulating substrate for exposing the contacts.