Electrical Connector Terminal Retention via Insert Molding and Separate Mounting
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Solution Overview
Problem
Existing electrical connectors for high-frequency signals face difficulties in assembling and maintaining stable terminal retention due to complex structures and unstable retention mechanisms.
Innovation Solution
An electrical connector design featuring a housing with a receptacle and a contact module, where first terminals are insert molded for stable retention and second terminals are mounted separately for easy assembly, utilizing Z-shaped insulative parts and barbs for secure engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If all terminals are inserted separately into the insulative part, then the assembly process becomes complex and time-consuming, but the terminal retention stability improves
Solution Approach 1:
The terminals are divided into two groups: first terminals that are insert-molded directly into the insulative part for stable retention, and second terminals that are separately mounted for easy assembly. This segmentation allows different retention methods to be applied to different terminal groups, resolving the contradiction between retention stability and assembly complexity.
Solution Approach 2:
The first terminals and the insulative part are merged through insert molding, creating a unified structure where the terminals are permanently retained within the insulative part. This merging eliminates the need for separate retention mechanisms for these terminals, simplifying the overall assembly while ensuring stable retention.
2Reliability
If all terminals are retained by insert molding, then terminal retention stability improves, but manufacturing difficulty and cost increase
Solution Approach 1:
The terminal retention system is segmented into two approaches: insert molding for first terminals and separate mounting for second terminals. This allows the manufacturing process to balance between retention stability and ease of manufacture by applying the more complex insert molding only where necessary.
Solution Approach 2:
Different retention methods are applied to different locations within the contact module. The first terminals receive the higher-quality, more stable insert molding retention, while the second terminals use the simpler separate mounting method, optimizing the overall manufacturing process.
3Ease of operation
If terminals are mounted separately for easy assembly, then assembly simplicity improves, but terminal retention stability deteriorates
Solution Approach 1:
The contact module is segmented into two terminal groups with different assembly methods. The second terminals use separate mounting for easy assembly, while the first terminals use insert molding for stable retention, ensuring that ease of operation does not compromise overall reliability.
4Reliability
If a complex retention mechanism is used for all terminals, then terminal retention stability improves, but assembly time increases
Solution Approach 1:
The terminal assembly process is segmented into two streams: insert molding for first terminals and separate mounting for second terminals. This segmentation allows parallel processing and reduces overall assembly time while maintaining retention stability for critical terminals.
Solution Approach 2:
The first terminals are pre-attached to the insulative part through insert molding before final assembly, ensuring their retention stability is established in advance. This preliminary action eliminates the need for complex retention mechanisms during final assembly, reducing assembly time.
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
The design simplifies assembly and enhances terminal retention stability, ensuring reliable contact and easy manufacturing, addressing the instability issues in existing connectors.
Implementation Method 1
The insulative part is retained in the housing by friction between an outer peripheral surface of the insulative part and an inner peripheral surface of the housing
Implementation Method 2
a set of first terminals insert molded with the insulative part
Data Source
AI summary
An electrical connector includes a housing (10) having a receptacle (14) for insertion of a plug connector and a contact module (20) inserted into the receptacle. The contact module having an insulative part (1), a first set of terminals (21) insert molded with the insulative part and a second set of terminals (22) separately mounted to the insulative part. Each of the first and second terminals has one end (211, 221) for mounting to an exterior substrate and another free end (215, 225). The free ends of the first terminals and the free ends of second terminals substantially extending along two opposite directions, respectively.