Electrical Connector Fixing Arms for Stable Module Assembly
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Solution Overview
Problem
Existing electrical connectors face difficulties in stable assembly and complex injection molding processes due to widely spaced wedges or protrusions, which complicate the mounting of contact modules to insulative housings and result in unstable fixation.
Innovation Solution
The design incorporates lower and upper receiving cavities with intermediate walls, featuring passageways and fixing arms that allow for easy assembly and reliable fixation of contact modules, eliminating the need for a slider core during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wedges or protrusions are used to fix the contact module to the insulative housing, then the contact module can be fixed to the housing, but the wedges or protrusions are separated too far apart making it difficult to mount and resulting in unstable fixation
Solution Approach 1:
The patent transitions from using discrete wedges or protrusions spaced apart in three-dimensional space to a continuous circumferential fixing structure. The fixing arms extend around the periphery of the contact module, providing continuous engagement with the insulative housing along the circumferential direction, thereby eliminating the spacing issue and improving both assembly ease and fixation stability.
Solution Approach 2:
The fixing structure is divided into multiple fixing arms that are distributed around the periphery of the contact module. Each fixing arm independently engages with the insulative housing, and the multiple arms work together to provide stable fixation. This segmentation allows for easier assembly while maintaining reliable fixation.
2Ease of manufacture
If a slider core is used to form wedges or protrusions during molding, then the fixing structures can be formed, but the injection molding process becomes complex
Solution Approach 1:
The patent removes the slider core component from the molding process entirely. The fixing arms are designed to be formed directly by the mold cavity without requiring additional slider cores or complex tooling. This extraction of the problematic slider core simplifies both the molding process and the overall device structure.
Solution Approach 2:
The fixing arms are integrated into the insulative housing as a single molded piece. The mold cavity directly forms the fixing arms without requiring separate tooling components like slider cores. This merging of the fixing structure into the main housing component simplifies the molding process and reduces tooling complexity.
3Ease of operation
If fixing arms are disposed on the insulating carriers close to each other, then assembly becomes easy and fixation becomes reliable, but the structure becomes more complex
Solution Approach 1:
The fixing arms serve multiple functions: they provide mechanical engagement with the insulative housing, distribute assembly forces evenly, and ensure proper positioning of the contact module. This multi-functionality allows for simple assembly without requiring additional complex components or mechanisms.
Data Source
AI summary
An electrical connector includes an insulative housing, a lower mating contact module, and an upper mating contact module. The insulative housing has a lower receiving cavity, an upper receiving cavity, and an intermediate wall located therebetween. The lower mating contact module has a lower insulating carrier and a set of lower mating contacts secured to the lower insulating carrier. The upper mating contact module has an upper insulating carrier and a set of upper mating contacts secured to the upper insulating carrier. The intermediate wall defines a lower passageway extending along a front-to-back direction and an upper passageway disposed above the lower passageway. The lower insulating carrier has a lower fixing arm inserted and fixed in the lower passageway, and the upper insulating carrier has an upper fixing arm inserted and fixing in the upper passageway.