Electrical Connector With Punch-Open Separation
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Solution Overview
Problem
The increasing density of electrical systems makes it difficult to separate adjacent electrical contacts in connectors due to their small pitch, complicating the assembly process and increasing costs and time.
Innovation Solution
The electrical connector design features a connection strip that initially connects adjacent contacts, with punch openings in the insulator allowing for the strip to be broken after mounting, facilitating easier separation and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the pitch between electrical contacts is reduced to increase density, then the component density increases, but the difficulty of separating adjacent electrical contacts increases
Solution Approach 1:
The connection strip is segmented into individual contact portions with separation zones between them. The punch openings create discrete separation points along the connection strip, allowing adjacent electrical contacts to be separated individually after mounting. This segmentation enables easy separation despite the small pitch between contacts by providing predetermined break points in the connection strip.
2Ease of operation
If adjacent electrical contacts are separated before mounting, then individual alignment is possible, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The electrical contacts are pre-assembled on the insulator as a connected array through the connection strip before separation. This preliminary mounting allows the entire array to be positioned and aligned in one operation, then the contacts are separated individually through the punch openings. This approach combines the benefits of bulk handling with individual separability, reducing assembly time while maintaining alignment capability.
3Ease of operation
If the connection strip is broken before mounting, then contacts can be positioned individually, but the assembly complexity and cost increase
Solution Approach 1:
The connection strip remains intact during the initial mounting phase, allowing the entire array of electrical contacts to be positioned and secured to the insulator as a unit. The breaking of the connection strip into individual contacts is performed as a subsequent preliminary action through the punch openings, before final assembly completion. This sequence simplifies the mounting process while enabling individual contact separation.
Data Source
AI summary
An electrical connector is provided for electrically connecting an electronic module to an electrical component. The electrical connector includes electrical contacts having mounting bases that are initially mechanically connected together by a connection strip. The connection strip extends along a connection path from the mounting base of one of the electrical contacts to the mounting base of the other electrical contact. The connection strip is broken along the connection path such that the electrical contacts are separated from each other. The electrical connector also includes a insulator having a module side and an opposite component side. The mounting bases of the electrical contacts are mechanically connected to the insulator on the module side of the insulator. The insulator includes a punch opening that extends into the module side of the insulator. The punch opening is aligned with the connection path of the connection strip and is configured to receive a punch tool for breaking the connection strip.