Connector Reducing Parts Count via Integrated Housing
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Solution Overview
Problem
Conventional connectors used in LCD TVs have a high manufacturing cost due to the number of parts required, which hinders price competition.
Innovation Solution
A connector design that reduces the number of parts by incorporating a printed circuit board with guide and locking holes, elastic locking units, and terminals that project outside the housing, allowing for mechanical coupling and electrical connection without a separate wafer, and using a fixing member to secure the housing and printed circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional connector design with multiple separate parts (wafer, housing, terminals) is used, then reliable electrical connection and mechanical stability are achieved, but manufacturing cost increases due to the number of parts
Solution Approach 1:
The patent merges the wafer and housing into a single integrated housing structure that directly receives terminals and provides mechanical support. The printed circuit board is also integrated into the housing assembly, eliminating the need for separate mounting structures. This consolidation reduces the number of parts while maintaining reliable electrical connections and mechanical stability.
Solution Approach 2:
The housing structure performs multiple functions simultaneously: it provides mechanical support for terminals, serves as the mounting structure for the printed circuit board, provides insulation, and enables electrical connections. The printed circuit board also serves dual purposes as both an electrical connection medium and a structural component of the connector assembly.
2Ease of manufacture
If the number of parts is reduced to lower manufacturing cost, then price competition is improved, but assembly precision and reliability may be compromised
Solution Approach 1:
While reducing the overall number of parts, the patent maintains functional segmentation within the integrated structures. The housing is divided into distinct regions for terminal reception, PCB mounting, and insulation. The printed circuit board is segmented into connection areas and structural support areas. This internal segmentation allows for precise manufacturing of each functional zone while maintaining cost efficiency through integration.
Solution Approach 2:
The patent employs precision engineering in the design of the integrated housing and PCB interfaces, specifying critical dimensions and tolerances for the guide holes, locking mechanisms, and terminal receptacles. By controlling key geometric parameters and assembly tolerances, the design ensures high assembly precision despite the reduced part count.
3Ease of operation
If conventional separate components (wafer, housing) are used, then ease of assembly is maintained, but the number of parts increases leading to higher costs
Solution Approach 1:
The printed circuit board is pre-assembled with the housing using guide holes and locking mechanisms before final terminal installation. The housing is pre-formed with integrated mounting structures and terminal receptacles, allowing for streamlined assembly operations. This preliminary assembly of structural components simplifies the overall assembly process while reducing the number of separate parts required.
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 reduces manufacturing costs by minimizing the number of parts while maintaining effective electrical connectivity and mechanical stability, enhancing competitiveness.
Implementation Method 1
the locking unit is formed of elastic material
Implementation Method 2
an elastic unit which is extended from the extension unit and bent toward the terminal downward with elastic force to be in contact with the top surface of the connection pad
Data Source
AI summary
The present invention provides a connector including: a printed circuit board including a guide hole and a locking hole; a plurality of connection pads provided on a top surface of the printed circuit board; a housing which is mounted on the printed circuit board and including a guide inserted into the guide hole and a locking unit inserted into the locking hole, which are protrudingly formed on a bottom surface of the housing; a plurality of terminals inserted and fixed into the housing so that one ends are positioned inside the housing and the other ends are projected to an outside of the housing; and terminal units in contact with top surfaces of the connection pads by being connected to the one ends of the terminals inside the housing.