Electrical Connector Header Stabilizing Structure for Precise Alignment
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Solution Overview
Problem
Existing electrical connectors face issues with components moving relative to each other, particularly in environments with tight tolerances, necessitating over-molding to maintain precise positioning.
Innovation Solution
The electrical connector incorporates stabilizing features such as stabilizing sections and latching arms that secure terminals and holders together, preventing unwanted movement in multiple directions without the need for over-molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If components are manufactured with movement or play to facilitate easy assembly, then ease of operation is improved, but manufacturing precision deteriorates
Solution Approach 1:
The connector is divided into separate components (housing, terminals, positioning features) that can be independently manufactured and assembled. The housing contains integrated positioning features that guide terminal placement, allowing components to be manufactured separately with standard tolerances while achieving precise final positioning through the modular design.
Solution Approach 2:
The patent introduces positioning features (such as positioning walls, positioning protrusions, and positioning recesses) that act as intermediaries between components. These features facilitate easy assembly by providing mechanical guidance and alignment, while simultaneously ensuring precise positioning of terminals relative to the housing and to each other.
2Manufacturing precision
If over-molding is used to control terminal location and prevent movement, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into the housing structure itself. The housing integrates positioning features, terminal retention mechanisms, and structural support functions into a single component. This eliminates the need for separate over-molding operations or additional positioning components, maintaining manufacturing precision while reducing overall device complexity.
Solution Approach 2:
The housing is designed with self-positioning features that automatically guide and secure terminals in the correct positions during assembly. The positioning walls and retention structures provide self-aligning and self-retaining functionality, eliminating the need for complex external positioning mechanisms or post-assembly adjustments.
Data Source
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AI summary
An electrical connector (10) having a housing having a pin plate holder (12) anda pin block holder (14). The pin block holder (14) has a pin block holderstabilizing section (30). The pin plate holder (12) has a pin plate holderstabilizing portion (62). With the pin block holder (14) and the pin plate holder(12) fully mated, the pin block holder stabilizing section (30) engages the pinplate holder stabilizing portion (62) to prevent the movement of the pin plateholder (12) relative to the pin block holder (14) in multiple directions.