Electrical Connector With Internal PCB And Soldered Wires
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Solution Overview
Problem
Existing electrical connectors face issues with reliable wire-to-contact connections and increased length due to wires being connected outside the connector, leading to potential loosening and increased dimensionality.
Innovation Solution
An electrical cable connector design featuring a base with a main body and mating tongue, insert-molded terminals, and an internal printed circuit board with a metallic shielding plate, where wires are mechanically and electrically connected to conductive pads on the board, and a two-stage insert-molding process unifies the base, terminals, and wires, ensuring secure connections while minimizing the connector's front-to-back dimension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If wires are connected to contacts outside the connector, then the connection structure is simpler, but the connector length increases and connection reliability decreases
Solution Approach 1:
The patent transitions from external wire connections (one-dimensional extension) to internal PCB-based connections (two-dimensional integration). Wires are soldered to conductive pads on the internal printed circuit board, which is positioned between the contacts and wire ends, creating a compact multi-layer arrangement that eliminates the need for wires to extend outside the connector housing.
Solution Approach 2:
The patent implements nested arrangement where the internal printed circuit board is positioned between the contacts and wire ends, with wires nested within the connector housing rather than extending externally. The shielding plate is also nested within the connector structure, creating a compact integrated assembly that reduces overall length while maintaining connection functionality.
2Ease of manufacture
If wires are connected to contacts outside the connector, then assembly is easier, but connection reliability decreases due to loosening
Solution Approach 1:
The patent segments the connection structure into distinct functional layers: contacts at the front, internal printed circuit board in the middle, and wire connections at the rear. This segmentation allows each component to be optimized independently while maintaining overall reliability. The internal PCB provides a stable mounting surface for wires, preventing the loosening issues associated with external connections.
3Ease of manufacture
If wires are connected externally, then manufacturing process is simpler, but connector dimension increases
Solution Approach 1:
The patent employs preliminary action by pre-soldering wires to conductive pads on the internal printed circuit board before final assembly. This preliminary connection ensures proper wire positioning and electrical connection, allowing the wires to be contained within the connector housing rather than extending externally, thus reducing the front-to-back dimension while maintaining manufacturing feasibility.
Data Source
AI summary
A first terminal module and a second terminal module are integrally assembled with the base, and each of the first terminal module and the second terminal module includes the insulator and the corresponding terminals embedded therein. The first terminal module and the second terminal module are stacked with each other with a metallic shielding plate therebetween. A plurality of wires are located behind the first and second terminal modules. An internal printed circuit board is located between the terminals and the wires in the front-to-back direction to respectively connect to the terminals and the wires. Each of the terminal modules is equipped with a metallic grounding bar connected to the printed circuit board and the wires.