Connector Housing Segmentation for Pin Alignment
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Solution Overview
Problem
Existing connector housings face challenges in handling and sealing electronic/electrical devices with header connectors, particularly due to difficulties in supporting and maintaining the spacing of terminal pins during mounting, exacerbated by the miniaturization of electrical connectors.
Innovation Solution
A connector housing design featuring a plastic mounting block with slots for contacts, a keeper for alignment and retention, and a latching system to secure the connector biscuit within the enclosure, ensuring proper alignment and support of terminal pins while allowing for secure connection and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the header connector is mounted to the electronic/electrical device first, then the connection is established, but handling and sealing become difficult
Solution Approach 1:
The connector housing is divided into two separate components: the header connector assembly and the enclosure. This segmentation allows the header connector to be manufactured and tested independently, then easily installed into the enclosure, improving both handling ease and connection reliability.
Solution Approach 2:
The header connector is pre-assembled with terminal pins and contact elements before being installed into the enclosure. This preliminary action ensures proper alignment and connection integrity is established before final assembly, making the overall assembly process easier while maintaining connection reliability.
2Ease of operation
If the header connector is mounted to the enclosure first, then handling is easier, but maintaining terminal pin spacing becomes difficult
Solution Approach 1:
The mounting block is pre-formed with precisely positioned slots that define the exact spacing and alignment for terminal pins. This preliminary preparation of the mounting structure ensures that when terminal pins are subsequently installed, their spacing precision is maintained without requiring complex adjustment procedures.
Solution Approach 2:
The mounting block serves as an intermediary component between the enclosure and the terminal pins. It provides a stable, pre-configured structure with precisely positioned slots that mediate the connection, ensuring accurate terminal pin spacing while simplifying the overall assembly process.
3Volume of moving object
If terminal pins are made smaller for miniaturization, then device size is reduced, but fragility increases
Solution Approach 1:
Retention tabs are pre-formed on the terminal pins during manufacturing. These tabs engage with corresponding features in the mounting block slots, creating a pre-established mechanical interlock that reinforces the terminal pins against fragility while maintaining their miniaturized dimensions.
Solution Approach 2:
The mounting block is made of a resilient material that provides mechanical support and reinforcement to the miniaturized terminal pins. This composite structure combines the small size of the terminal pins with the strength and flexibility of the mounting block material, resolving the contradiction between miniaturization and fragility.
Data Source
AI summary
A connector housing is provided for an electronic/electrical device, which may include a printed circuit board. The connector housing includes a header connector secured to an enclosure. The header connector includes a plastic mounting block defining a plurality of slots. A plurality of contacts is at least partially disposed in the slots of the mounting block, respectively. The contacts each have a first section and a second section. The first section includes a connector end and the second section includes a plurality of retention tabs and a tail end for connection to the electronic/electrical device. The retention tabs extend in the lateral direction and engage the mounting block to help secure the contacts to the mounting block. A keeper is connected to the mounting block such that the tail ends of the contacts protrude from an outer surface of the keeper.