Standardized Connector Module Holders for Lower-Cost Terminal Integration
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Solution Overview
Problem
Existing connectors require two different sets of molds for manufacturing due to size and structural differences between terminals, leading to increased manufacturing costs and complex structures.
Innovation Solution
A connector module design that uses standardized holders for terminal modules, eliminating the need for complex molds and reducing manufacturing costs by simplifying the structure of the second holder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two different sets of molds are used to manufacture the first and second retaining bodies due to size and structure differences, then the terminals can be held securely, but manufacturing costs increase
Solution Approach 1:
The patent applies universality by designing the second retaining body to have the same structure as the first retaining body, allowing a single mold design to manufacture both retaining bodies. This standardized design enables the same holder structure to accommodate different terminal types (first, second, third, and fourth terminals) through configurable terminal receiving spaces, thereby reducing manufacturing costs while maintaining secure terminal holding.
2Adaptability or versatility
If the rear of the second holder is inserted into the first holder to accommodate different terminal sizes, then all terminals can be integrated, but the structure becomes complex and manufacturing costs increase
Solution Approach 1:
The patent applies segmentation by dividing the connector into separate first and second holders that are positioned side-by-side rather than nested. Each holder independently accommodates specific terminals (first holder for first and second terminals, second holder for third and fourth terminals). This segmentation eliminates the need for complex nested structures while maintaining the ability to integrate different terminal types through standardized mounting interfaces on the insulating substrate.
3Adaptability or versatility
If two different sets of molds are used for the first and second retaining bodies, then the different terminal sizes can be accommodated, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies universality in the molding process by designing a single standardized retaining body structure that can be used for both the first and second holders. The retaining body includes configurable terminal receiving spaces that can accommodate terminals of different sizes and types. This universal mold design simplifies the manufacturing process by eliminating the need for separate mold sets while maintaining the ability to accommodate various terminal dimensions through the flexible internal geometry of the standardized holder structure.
Data Source
AI summary
A connector module includes: 1) a first terminal module comprising a row of first terminals; 2) a second terminal module comprising a row of second terminals; and 3) a first holder, wherein the first terminal module and the second terminal module are respectively installed on the top and bottom of the first holder. The connector module further includes: 4) a third terminal module comprising a row of third terminals; 5) a fourth terminal module comprising a row of fourth terminals; and 6) a second holder, wherein the third and fourth terminal modules are respectively installed on the top and bottom of the second holder.