Connector Insert Structure for Compact Bus Bar Assembly
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Solution Overview
Problem
Existing connectors for attaching a matching connector to a circuit board have issues with multiple parts, complex assembly processes, large dimensions, and inability to interconnect with a three-layer cascading bus bar, leading to increased mold costs and integration challenges.
Innovation Solution
A connector design featuring a housing with integrally formed support arms for power supply terminals, reducing parts and assembly complexity, and incorporating detection terminals for precise insertion, along with guide arms for stable connection, enabling miniaturization and reliable electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If auxiliary cantilevers made of stainless steel are used to support power supply terminals, then the connector can be manufactured with traditional methods, but the number of parts increases and mold expenses increase
Solution Approach 1:
The patent integrates the support function previously performed by separate stainless steel auxiliary cantilevers into the insert itself. The insert is designed with integrated support structures that directly support the power supply terminals, eliminating the need for separate cantilever components and reducing the total part count while maintaining manufacturability
Solution Approach 2:
The insert is designed to perform multiple functions: it provides structural support for power supply terminals, electrical insulation, and mechanical stability. By making the insert multi-functional, the patent eliminates the need for separate auxiliary cantilevers that only provided support, thereby reducing part count and mold expenses
2Reliability
If auxiliary cantilevers are crimped and fixed to power supply terminals, then the terminals can be securely supported, but the assembly process becomes more complicated
Solution Approach 1:
The support function and terminal fixation are merged into the insert structure itself. The insert includes integrated support arms or protrusions that directly hold the power supply terminals in position without requiring separate crimping operations, thereby maintaining reliability while simplifying assembly
Solution Approach 2:
The insert is designed with self-supporting structures that automatically hold and position the power supply terminals during assembly. The terminal supports are built into the insert geometry, allowing terminals to be simply placed and secured without complex crimping or additional fastening steps
3Ease of operation
If ground terminals are constructed as L-shaped for easy mounting to housing, then mounting is simplified, but the lateral dimensions of the housing and connector increase
Solution Approach 1:
Instead of extending ground terminals laterally in two dimensions (L-shape), the patent reorients them to extend vertically or along the longitudinal axis of the connector. This dimensional change allows easy mounting to the housing while minimizing the lateral footprint and enabling better integration
4Adaptability or versatility
If a cable is attached to one end of the housing, then the connector can be connected to external systems, but direct attachment to the circuit board becomes difficult
Solution Approach 1:
The housing is designed with multi-functional capabilities: it can accommodate cable attachments for external connections while also providing integrated mounting features for direct circuit board attachment. This dual functionality allows the connector to be mounted directly to the circuit board while still maintaining the option for cable connections
Data Source
AI summary
A connector includes a housing, two power supply terminals, and an insert inserted into the housing. The insert includes a base to which the two power supply terminals are mounted, and two support arms extending from the base. Free ends of the two support arms are positioned to support a respective power supply terminal.