Wire-to-Board Connector Protrusion Engagement
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Solution Overview
Problem
Existing wire-to-board connectors face issues with reduced structural strength due to elasticity loss or breakage of elastic arms after repeated connections and disconnections, complicating miniaturization and increasing manufacturing costs.
Innovation Solution
A wire-to-board connector design featuring solid protrusions in engaging holes enhances connection strength, simplifies structure, and facilitates miniaturization by using a dielectric housing with conductive terminals and positioning recesses, eliminating the need for elastic arms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If elastic arms are used to engage with board-to-wire connectors, then connection strength is improved, but structural reliability deteriorates after multiple repeated connections and disconnections due to elasticity loss
Solution Approach 1:
The patent removes the elastic arms from the connector structure entirely. Instead of using elastic arms that lose elasticity over time, the invention employs a rigid housing with integrated engagement features (protrusions and recesses) that maintain stable mechanical engagement without relying on elastic deformation, thereby eliminating the reliability degradation issue
Solution Approach 2:
Rather than using flexible elastic arms to achieve engagement, the patent inverts the approach by using a rigid housing structure with precisely positioned protrusions and recesses. The engagement is achieved through complementary geometric features rather than elastic deformation, reversing the traditional mechanism while improving reliability
2Strength
If elastic arms with z-shaped structure are used, then connection strength is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the engagement function into the housing structure itself. The protrusions are directly formed as integral parts of the housing, eliminating the need for separate elastic arm components. This consolidation reduces part count, simplifies assembly, and lowers manufacturing complexity while maintaining engagement functionality
Solution Approach 2:
The housing structure serves multiple functions: it provides mechanical support, guides cable positioning, and enables engagement with board-to-wire connectors through integrated protrusions. This multi-functionality eliminates the need for dedicated elastic arms, simplifying the overall structure
3Strength
If elastic arms are used for engagement, then connection strength is improved, but ease of manufacture deteriorates due to complicated mold requirements
Solution Approach 1:
By removing the elastic arms entirely and replacing them with rigid housing protrusions, the patent eliminates the need for complex multi-cavity molds or specialized elastic component molding processes. The simplified geometry allows for easier injection molding with standard tools, improving manufacturability
Solution Approach 2:
Instead of molding complex elastic arm structures with z-shapes and integration points, the patent inverts the approach by using simple rigid protrusions that can be formed with basic mold features, significantly reducing manufacturing complexity and tooling costs
4Volume of moving object
If wire-to-board connectors are downsized, then product miniaturization is achieved, but structural strength deteriorates making them unable to withstand repeated connections
Solution Approach 1:
The patent applies local quality by concentrating structural strength at critical engagement points through precisely positioned protrusions and recesses. Rather than uniformly increasing overall size, the design optimizes local geometry at the engagement interface to maintain high connection strength despite reduced overall connector dimensions
Solution Approach 2:
The housing is made from high-strength plastic material that provides sufficient mechanical strength for repeated connections even in miniaturized form. The material selection and structural design work together to compensate for reduced size while maintaining engagement durability
Data Source
AI summary
A wire-to-board connector for connecting with a board-to-wire connector that includes a plastic body having a raised portion and two coupling portions, wherein the raised portion defines multiple through holes, each coupling portion is formed with an upright support having an enlarged top end, and multiple conductive terminals are fitted through the multiple through holes, wherein each conductive terminal has a fixed section, a solder section, and a connecting section. The wire-to-board connector comprises a dielectric housing and multiple conductive terminals. The dielectric housing defines two engaging holes and multiple positioning recesses. The conductive terminals of the wire-to-board connector are disposed in the positioning recesses for electrical connection to the connecting sections, wherein a protrusion is formed on an inner surface of each engaging hole, corresponding to the enlarged top end.