Connector Assembly Structure for Low-Insertion Stable Contact

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Solution Overview

Problem

Existing connectors require high insertion forces during mating, which can damage terminals and housings, and the positioning of contact points is unstable, leading to unreliable electrical connections.

Innovation Solution

The connector design includes resiliently deformable extending portions with controlled gaps and restrictions to allow reduced insertion force and precise positioning of contact points, using interposing portions and housing configurations to stabilize terminal alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the support contact point functions as the mating lock portion and exerts great reaction force on the contact protrusion, then the lock engagement is secure, but the insertion force required for mating increases significantly

Engineering Contradiction:
Improvelock engagement reliabilityVSAvoidinsertion force
Core Design Contradiction:
ReliabilityVSForce

Solution Approach 1:

The patent divides the contact point into two separate functional elements: a support contact point for bearing load and a separate mating lock portion for engagement. This segmentation allows each element to perform its specific function without the support contact point needing to provide locking force, thereby reducing insertion force while maintaining reliable lock engagement through the dedicated lock portion.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent introduces a resilient member as an intermediary between the contact protrusion and the mating structure. This resilient member absorbs the reaction force during engagement, reducing the insertion force required while ensuring reliable lock engagement. The intermediary element decouples the force transmission path from the locking mechanism.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Force

If the terminal is made resiliently deformable to reduce insertion force, then insertion force is reduced, but the positioning accuracy of contact points deteriorates

Engineering Contradiction:
Improveinsertion forceVSAvoidcontact point positioning accuracy
Core Design Contradiction:
ForceVSManufacturing precision

Solution Approach 1:

The patent applies different mechanical properties to different parts of the terminal structure. The terminal body is made resiliently deformable to reduce insertion force, while the contact points and their supporting structures are designed with higher rigidity and precision to maintain positioning accuracy. This local differentiation of mechanical properties allows simultaneous achievement of low insertion force and high positioning precision.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent incorporates preliminary positioning features such as guide portions and predetermined positioning structures that establish accurate contact point alignment before the resilient deformation occurs during mating. This preliminary action ensures that even though the terminal deforms resiliently during engagement, the contact points maintain their designed positional relationships.

Inventive Principle:
Principle #10Preliminary action

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 achieves a reduced insertion force and stable, accurate electrical contact between terminals, ensuring reliable connections without damage.

Implementation Method 1

the extending portion 440 is resiliently deformable

Methodology Applied
Scientific EffectElasticity: Elasticity

Data Source

PatentUS12469996B2Connector and connector assembly
Publication Date: 2025.11.11 JAPAN AVIATION ELECTRONICS IND LTD
  • US12469996B2 patent drawing
  • US12469996B2 patent drawing
  • US12469996B2 patent drawing

AI summary

A connector comprises a plurality of terminals and a housing. The housing has an interposing portion extends in an up-down direction. The interposing portion has a first side portion and a second side portion in a width direction perpendicular to the up-down direction. Each of the terminals has an insertion end portion and a second extending portion. The second side portion has an allowance portion and a restriction portion. The allowance portion is nearer to the insertion end portion than the restriction portion in the up-down direction. The connector has a gap between the allowance portion and the second extending portion in the width direction. The allowance portion allows partial movement of the second extending portion into the gap. The restriction portion is in contact with the second extending portion in the width direction without any gap and thereby restricts movement of the second extending portion in the width direction.