Electrical Connector Terminal Positioning via Insert Molding
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Solution Overview
Problem
The increasing number of terminals in electronic devices leads to difficulties in maintaining precise and uniform spacing, causing electromagnetic interference and affecting data transmission, with prior methods like bending terminals perpendicularly resulting in reduced data transmission ability and assembly challenges.
Innovation Solution
The use of an insert molding process to embed terminals with contact and inclined sections within an insulated main body and positioning member, ensuring neat and uniform arrangement, and allowing for precise positioning without affecting alignment or increasing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of terminals is increased to meet data transmission requirements, then data transmission capability is improved, but maintaining precise and uniform spacing between terminals becomes more difficult
Solution Approach 1:
The terminal assembly is segmented into modular units with standardized pitch distances. Each terminal group is independently positioned using positioning members that divide the overall terminal array into manageable segments, making it easier to maintain uniform spacing across a large number of terminals.
Solution Approach 2:
The positioning members are designed to automatically guide terminal placement through self-aligning features such as positioning grooves and protrusions. The structure itself provides the positioning function without requiring additional external fixtures or complex assembly processes.
2Object-affected harmful factors
If terminals are arranged in staggered pattern to reduce electromagnetic interference, then electromagnetic interference is reduced, but uniformity and alignment of terminal sections are affected
Solution Approach 1:
The positioning members incorporate asymmetric positioning features that accommodate staggered terminal arrangements. The positioning grooves are designed with specific angular orientations that allow terminals in adjacent rows to be offset while maintaining precise control over the staggered pattern, reducing electromagnetic interference while preserving alignment uniformity.
3Ease of manufacture
If terminals are bent perpendicularly and mounted to insulated member, then assembly is simplified, but data transmission ability is decreased
Solution Approach 1:
Instead of bending terminals perpendicularly and then mounting them, the invention inverts the sequence by first mounting terminals at their final angled positions using the positioning members, and then forming the bending. This ensures that the terminal angles are precisely controlled during the forming process, maintaining data transmission capability while achieving the desired bent configuration.
4Manufacturing precision
If insert molding process is used to embed terminals in insulated main body, then terminal positioning precision is improved, but production complexity increases
Solution Approach 1:
The invention merges the positioning member formation and terminal embedding into a single integrated insert molding process. The positioning members are formed directly within the insulated main body during the same molding cycle, eliminating the need for separate positioning fixture fabrication and assembly steps, thus reducing overall production complexity while maintaining high positioning precision.
Data Source
AI summary
An electrical connector includes a positioning member; an insulated main body enclosing the positioning member from above and a plurality of terminals. Each terminal has a contact section embedded within a tongue plate of the insulated main body and an inclined section embedded partially within the positioning member via an insert-molding process. When the inclined section is further bent relative to the contact section, the uniform spacing and alignment among the terminals is maintained precisely due to the insert-molding process of the terminals in the insulated main body and the positioning member.