Electrical Connector Housing Layout for Simpler Electroplating
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Solution Overview
Problem
The manufacturing process of conventional electrical connectors for Bluetooth headsets is complex due to the use of shielding materials and chemical liquids in the electroplating process, which complicates the production and increases material usage.
Innovation Solution
The electrical connector design includes an insulating housing with staggered perforations and leg recesses, allowing for insert molding of power and ground terminals before electroplating, thereby omitting the need for shielding materials and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If shielding material is used in the electroplating process, then the electroplating quality is improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent applies preliminary action by performing electroplating on the contacts before assembling them into the housing, rather than after assembly. This allows the electroplating process to be completed on exposed contacts without requiring shielding materials or complex masking procedures, thereby maintaining electroplating quality while simplifying the manufacturing process
Solution Approach 2:
The patent extracts the electroplating operation from the assembled connector structure and performs it on separate, exposed contacts before final assembly. This separation eliminates the need for shielding materials that would otherwise be required to protect non-plating areas, reducing manufacturing complexity while preserving plating quality
2Manufacturing precision
If shielding material and chemical liquid are used in electroplating, then the electroplating quality is improved, but the manufacturing time increases
Solution Approach 1:
The patent performs electroplating as a preliminary operation on exposed contacts before assembly, eliminating the time-consuming steps of applying and removing shielding materials and chemical liquids that would be required if electroplating were performed after assembly. This maintains plating quality while significantly reducing total manufacturing time
Solution Approach 2:
The patent skips the intermediate steps of shielding and chemical liquid removal by performing electroplating on already-exposed contacts. This direct approach eliminates unnecessary process steps, reducing manufacturing time while maintaining electroplating quality through proper process control
3Manufacturing precision
If shielding material is used in the electroplating process, then the electroplating quality is improved, but the material cost increases
Solution Approach 1:
The patent extracts the electroplating operation to be performed on exposed contacts before assembly, eliminating the need for shielding materials entirely. This approach maintains electroplating quality by ensuring proper plating coverage while reducing material costs by removing unnecessary shielding and chemical liquid consumption
Solution Approach 2:
The patent eliminates the use of expensive shielding materials and chemical liquids by performing electroplating on exposed contacts. This approach uses no disposable shielding materials, directly reducing material costs while maintaining plating quality through efficient process design
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 approach improves manufacturing efficiency and reduces material usage by allowing electroplating before soldering, resulting in a more streamlined production process and cost-effective electrical connector assembly.
Implementation Method 1
the soldering legs are electroplated rhodium-ruthenium alloy
Implementation Method 2
soldering the power leg with the power contact to form a power terminal, soldering the ground leg with the ground contact to form a ground terminal
Data Source
AI summary
An electrical connector includes an insulating housing, a power leg, a ground leg, a power contact and a ground contact. The insulating housing has a peripheral wall. At least two perforations are defined on the peripheral wall. At least two leg recesses are formed on the peripheral wall. The perforations and the leg recesses are staggered along the peripheral wall. The power leg and the ground leg are both received in the peripheral wall of the insulating housing and are both have leg portions being exposed from the leg recesses. The power contact and the ground contact are both located in the perforations. As described above, manufacture material of the electrical connector is saved.