Electrical Connector Assembly With Perpendicular Cable Routing
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Solution Overview
Problem
Existing connector assemblies face challenges in miniaturization and reliability due to the need for bending cables, which occupy space and are prone to damage.
Innovation Solution
The introduction of an adapter circuit board that electrically connects the conductive terminal to the cable, allowing the cable to extend perpendicularly, eliminating the need for bending and enhancing the reliability of the electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cable is directly connected to the plug conductive terminal, then the electrical connection is simple, but the cable needs to be bent which occupies space and reduces reliability
Solution Approach 1:
The patent introduces an adapter circuit board as an intermediary component between the conductive terminal and the cable. The adapter circuit board includes a mounting portion that receives the conductive terminal and another portion for connecting the cable, eliminating the need for cable bending while maintaining electrical connection functionality.
Solution Approach 2:
The patent changes the spatial arrangement by using the adapter circuit board to route the cable in a different direction (perpendicular to the conductive terminal extension direction). This dimensional change eliminates the need for cable bending and reduces space occupation.
2Reliability
If the cable is bent to connect directly to the conductive terminal, then the connector structure is simple, but the cable is prone to damage and miniaturization is hindered
Solution Approach 1:
The adapter circuit board serves as a mediator that absorbs the spatial transition, allowing the cable to connect without bending. This protects the cable from damage points while enabling more compact connector design.
Solution Approach 2:
The patent segments the connection function into two parts: the conductive terminal handles electrical contact while the adapter circuit board handles cable routing. This segmentation allows independent optimization of each component, protecting the cable while enabling miniaturization.
3Volume of moving object
If the cable is bent at 90° to the conductive terminal, then the connection is achieved, but large space is reserved at the bending position which prevents miniaturization
Solution Approach 1:
The adapter circuit board enables the cable to extend in a direction perpendicular to the conductive terminal extension direction, utilizing a different spatial dimension. This eliminates the need for large space reservation at bending positions while achieving the same electrical connection function.
Solution Approach 2:
The adapter circuit board mediates the spatial transition between the conductive terminal and the cable, allowing perpendicular arrangement without requiring large bending space. This intermediary component enables compact connector design.
Data Source
AI summary
An electrical connector includes an insulating body, a conductive terminal, an adapter circuit board and a cable. The insulating body includes a terminal receiving groove extending along a first direction. The conductive terminal includes a fixing portion, a mating portion and a mounting portion. The mating portion is located in the terminal receiving groove. The transfer circuit board includes a conductive hole. The mounting portion of the conductive terminal is inserted into the conductive hole. The cable is electrically connected to the adapter circuit board. The cable extends in a second direction perpendicular to the first direction. A method for making the electrical connector and a connector assembly having the electrical connector are disclosed.