Connector With Segmented Contact Holder For Alignment
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Solution Overview
Problem
Conventional connectors face issues with contact alignment and stability due to groove pitch reduction and thermal deformation during reflow heating, leading to unreliable fixation and increased production costs from manual correction steps.
Innovation Solution
A connector design featuring a contact holder with integral second contacts and projecting portions, which maintains alignment and stability through integral molding and reduces resin thickness, allowing for adjustable contact thickness and impedance control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of contacts to be mounted increases, then the contact capacity is improved, but the pitch of the grooves decreases leading to reduction in resin thickness between adjacent grooves
Solution Approach 1:
The connector is divided into two separate structures: a main body with grooves for first contacts, and a contact holder with additional grooves for second contacts. This segmentation allows the first contacts to be held with adequate resin thickness in the main body, while the contact holder provides a separate mounting structure for the additional second contacts, thus resolving the conflict between increasing contact capacity and maintaining sufficient resin thickness for manufacturing precision.
2Quantity of substance
If the groove pitch is reduced to accommodate more contacts, then the contact capacity is improved, but the stability of contact press-fitting deteriorates
Solution Approach 1:
By separating the contact mounting into two independent systems (main body for first contacts, contact holder for second contacts), each system can be optimized for its specific contact count and pitch requirements. The contact holder is specifically designed to provide adequate press-fitting stability for the second contacts, thus maintaining reliability while enabling higher overall contact capacity.
Solution Approach 2:
The contact holder acts as an intermediary component between the main body and the second contacts. It provides a dedicated mounting structure that ensures stable press-fitting for the second contacts, isolating them from the pitch reduction issues in the main body and maintaining reliable electrical connections.
3Manufacturing precision
If manual sizing or correcting steps are added to the assembly process, then the contact alignment precision is improved, but the production efficiency and cost deteriorate
Solution Approach 1:
The contact holder is pre-formed with precisely positioned grooves for the second contacts through integral molding. This preliminary action of creating pre-positioned mounting structures eliminates the need for subsequent manual sizing or correcting steps, thereby maintaining high contact alignment precision while preserving production efficiency and avoiding additional manufacturing costs.
Solution Approach 2:
The invention changes the manufacturing parameter approach from post-assembly manual correction to pre-formation through integral molding. The contact holder is manufactured with precisely controlled groove positions and dimensions directly in the molding process, achieving high alignment precision without requiring subsequent manual intervention, thus maintaining productivity.
Data Source
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AI summary
Provided is a connector capable of holding a plurality of contacts in alignment. The connector (C) includes a main body (1), a plurality of contacts (3) to be electrically connected to a connection object and a contact holder (4) holding the plurality of contacts (3) in juxtaposition. The main body (1) includes a fixing portion (15) for fixing the contact holder (4). The plurality of contacts (3) are fixedly held to the contact holder (4) through integral molding therewith.