Connector Housing Alignment Without Compensation Plate
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Solution Overview
Problem
Conventional connectors require a compensation plate for improved alignment accuracy, which increases the number of parts, assembly time, and can lead to mechanical issues such as contact deformation and solder cracking due to thermal expansion differences.
Innovation Solution
A connector design where the housing has a long holding part to securely position contacts without a compensation plate, featuring a dual insertion hole system and flange parts to maintain alignment and prevent deformation, allowing for precise contact positioning and reduced part count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a compensation plate is used to improve alignment accuracy of contacts, then alignment precision is improved, but the number of parts increases and assembly complexity increases
Solution Approach 1:
The patent integrates the alignment function directly into the housing structure by extending the holding part of the housing to protrude beyond the contact insertion position. This merging of the housing and alignment features eliminates the need for a separate compensation plate, reducing part count while maintaining alignment accuracy.
Solution Approach 2:
The holding part of the housing serves multiple functions: it holds the contacts in place, provides structural support, and extends beyond the contact insertion position to provide alignment guidance. This multi-functionality eliminates the need for dedicated alignment components.
2Manufacturing precision
If a compensation plate is used to improve alignment accuracy, then alignment precision is improved, but assembly time increases
Solution Approach 1:
By integrating the alignment function into the housing structure itself, the patent eliminates the need for separate alignment operations. The extended holding part automatically provides alignment guidance during contact insertion, reducing assembly steps and time.
3Manufacturing precision
If a compensation plate is used for alignment, then alignment accuracy is improved, but thermal stress and solder cracking risk increase
Solution Approach 1:
The patent uses the housing material itself (same material as the main connector body) for the extended holding part that provides alignment, rather than introducing a different material like a compensation plate. This homogeneity ensures matching thermal expansion coefficients, preventing thermal stress and solder cracking.
4Manufacturing precision
If the holding part is extended to improve alignment, then alignment accuracy is improved, but the length of the connector increases
Solution Approach 1:
The patent extends only the holding part of the housing locally where contacts are inserted, rather than extending the entire connector. This localized extension provides alignment guidance precisely where needed without unnecessarily increasing overall connector dimensions.
Data Source
AI summary
A connector includes a housing and contacts. Each of the contacts includes a leading end, a connecting part, a held part, and a flange part. The housing has a holding part having a contact insertion hole into which the held part is inserted. The contact insertion hole includes: a first insertion hole in which a side surface of the held part of the contact is held; a second insertion hole formed in a size that holds one opposite side surface of the held part of the contact, and having a space on the other opposite side surface side, the second insertion hole being formed to be longer than the first insertion hole; and a flange holding part. The held part of the contact is made longer than the leading end of the contact. This configuration can improve alignment accuracy of the contacts without using a compensation plate.