Connector With Built-In Substrate Miniaturization

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Solution Overview

Problem

Connectors with built-in substrates require increased size due to the need to connect all terminals at a predetermined interval, making it challenging to fit them in a practical size and shape.

Innovation Solution

A connector design featuring a chain terminal with a first tab portion and a second tab portion protruding in different directions, where the chain terminal is installed in a housing with the substrate connected to the second tab portion, allowing for reduced substrate size and a practical outer shape, and a manufacturing method involving intermediate molded-object molding and chain terminal molding steps to create the chain terminal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If all terminals are connected to a substrate at a predetermined interval, then the connector achieves reliable electrical connections, but the substrate size increases making it difficult to fit in a practical size and shape

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidsubstrate area

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The terminal connections are segmented into two groups: first tab portions connected to the substrate and second tab portions connected to the chain portion. This segmentation allows only some terminals to be connected to the substrate, reducing the required substrate area while maintaining reliable electrical connections through the chain terminal structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The chain terminal extends connections in multiple directions (first tab portions in one direction, second tab portions in another direction) rather than requiring all connections in a single plane on the substrate. This dimensional approach allows compact substrate design while achieving comprehensive terminal connectivity

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Area of stationary object

If the substrate size is reduced to achieve a compact connector, then the outer shape becomes practical, but the area available for connecting terminals to the substrate is insufficient

Engineering Contradiction:

Improvesubstrate areaVSAvoidterminal connection capability

Core Design Contradiction:

Area of stationary objectVSAdaptability or versatility

Solution Approach 1:

The chain terminal serves multiple functions: it provides electrical connection paths through first tab portions to the substrate, extends connections through second tab portions in different directions, and maintains structural integrity. This multi-functionality allows compact substrate design while preserving comprehensive terminal connection capability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The chain terminal acts as an intermediary element between the substrate and the external terminals. It receives connections from the substrate through first tab portions and distributes them to second tab portions in various directions, enabling compact substrate design while maintaining versatile terminal connectivity

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11600940B2Connector with built-in substrate and method of manufacturing chain terminal of the connector with built-in substrate

Publication Date: 2023.03.07 YAZAKI CORP

AI summary

A connector with a built-in substrate includes a chain terminal including a chain portion, a first tab portion configured to protrude from the chain portion in a predetermined direction, a second tab portion configured to protrude from the chain portion in a direction different from a protrusion direction of the first tab portion; an inner housing in which the chain terminal is installed such that the first tab portion and the second tab portion protrude; and a substrate connected to the second tab portion protruding from the inner housing.