Connector Insert Assembly with Termination Slots for Mass Wire Termination
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Solution Overview
Problem
Existing modular connectors in the telecommunications industry face challenges in achieving reliable and cost-effective manufacturing due to the time-consuming and costly process of manually wrapping and soldering wire windings, which affects electrical and noise performance and reliability.
Innovation Solution
The development of a multi-port connector assembly with a removable insert structure featuring termination grooves and conductive ends secured by a substrate, allowing for mass termination techniques that eliminate the need for manual wire wrapping and soldering, thereby reducing manufacturing time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual wire wrapping and soldering is used for wire wound electronic components, then reliable electrical connections are achieved, but manufacturing time and cost increase significantly
Solution Approach 1:
The invention segments the connector into a housing and a removable insert assembly. The insert assembly contains pre-terminated wire wound electronic components that can be manufactured separately and then quickly installed into the housing, eliminating the need for manual wire wrapping and soldering during final assembly while maintaining reliable electrical connections through pre-soldered terminations on the insert
Solution Approach 2:
The wire wound electronic components and their terminations are prepared in advance on the removable insert assembly before final assembly. The insert is pre-equipped with all necessary electronic components and their electrical connections are established beforehand, allowing for efficient final assembly without time-consuming manual termination processes
2Reliability
If manual wire wrapping and soldering is used for wire wound electronic components, then reliable electrical connections are achieved, but manufacturing cost increases significantly
Solution Approach 1:
The connector is divided into separable parts with the insert assembly containing pre-manufactured electronic components. This segmentation allows for specialized manufacturing of the insert using cost-effective automated processes while maintaining high reliability through controlled pre-termination, reducing overall manufacturing cost compared to complete manual assembly
Solution Approach 2:
The removable insert assembly serves as a reusable template or copy that can be manufactured once with all electronic components properly terminated and then replicated multiple times by simply replacing inserts in the housing, significantly reducing per-unit manufacturing cost while maintaining consistent quality
3Productivity
If removable insert structure with termination grooves is used, then manufacturing efficiency is improved, but device complexity increases
Solution Approach 1:
The connector is segmented into a simple housing and a removable insert with integrated termination grooves. While the insert itself has complex features, the housing remains simple and the segmentation allows for specialized manufacturing of the complex insert using automated processes, improving overall manufacturing efficiency despite the increased structural complexity of the insert component
Data Source
AI summary
An exemplary connector insert assembly, and methods of manufacture and use thereof. In one embodiment, the connector insert assembly comprises an insert body assembly consisting of two insert body elements made from a high-temperature polymer. The insert body assembly includes an electronic component receiving cavity that is configured to receive any number of electronic components, including without limitation, chip chokes and wire wound electronic components. The insert body assembly includes a wire termination feature that includes termination slots that position the wire ends of the wire wound electronic components adjacent to a substrate to which the wire ends are ultimately to be secured. The wire ends are then secured to the substrate using, for example, a mass termination technique. The aforementioned connector insert assembly can then be inserted into a single or multi-port connector assembly. Methods of manufacturing the aforementioned single or multi-port connector assemblies are also disclosed.