Electrical Connector Terminal Alignment via Abutment Portions
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Solution Overview
Problem
Existing electrical connectors face issues with terminal tilting due to gaps between extension portions and housing apertures, leading to misalignment and degraded signal transmission characteristics.
Innovation Solution
The electrical connector features sheet metal terminals with first and second abutment portions that abut interior wall surfaces of the housing, maintaining the terminals in their standard position despite gaps, preventing tilting and ensuring stable contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If terminal-retaining apertures are formed with width dimensions sufficient to accommodate terminal insertion, then ease of manufacture is improved, but terminal stability deteriorates due to large gaps causing tilting
Solution Approach 1:
The terminal-retaining aperture is divided into two functional zones: an upper insertion portion with larger width for easy terminal insertion, and a lower retaining portion with smaller width for stable terminal retention. This segmentation allows the aperture to fulfill both insertion convenience and retention stability requirements simultaneously.
Solution Approach 2:
Different sections of the terminal-retaining aperture are given different width dimensions according to their specific functions. The upper section has larger width to facilitate insertion, while the lower section has smaller width to prevent tilting and ensure stability. This local differentiation of geometric properties resolves the contradiction between ease of insertion and retention stability.
2Ease of operation
If extension portions are retained by secured projections in terminal-retaining apertures, then ease of operation is improved, but manufacturing precision deteriorates due to assembly errors causing tilting
Solution Approach 1:
The terminal-retaining aperture is pre-formed with a narrowed lower portion that automatically guides and constrains the extension portion during insertion. This preliminary geometric constraint prevents misalignment and tilting before the secured projections engage, compensating for potential assembly errors and ensuring precise terminal alignment.
Solution Approach 2:
The narrowed lower portion of the terminal-retaining aperture acts as an intermediary guiding structure between the extension portion and the secured projections. It provides gradual alignment and constraint during the mounting process, preventing direct impact and misalignment that would occur with a uniform aperture width.
3Ease of manufacture
If gaps exist between extension portions and aperture wall surfaces, then ease of manufacture is improved, but signal transmission quality deteriorates due to terminal tilting and misalignment
Solution Approach 1:
The terminal-retaining aperture is segmented into an upper insertion portion with larger width (allowing gaps for ease of manufacture) and a lower retaining portion with smaller width (maintaining tight fit for signal quality). This segmentation allows gaps to exist only where they do not compromise terminal alignment and signal transmission.
Solution Approach 2:
The aperture width is varied along the vertical dimension (through-thickness direction) rather than maintaining a uniform width. The upper portion has larger width for manufacturing ease, while the lower portion has smaller width for maintaining tight contact and preventing tilting, thus preserving signal transmission characteristics.
Data Source
AI summary
An electrical connector for circuit boards whose terminals 70 have a first abutment portion 72 which, within a terminal retaining portion 63A, is located closer to one interior wall surface of the above mentioned terminal retaining portion 63A opposed to one major face of said retained portion 71 than to said one major face and which is abuttable against said one interior wall surface, and a second abutment portion 73, which is located closer to the other interior wall surface of the terminal retaining portion 63A opposed to the other major face of the above mentioned retained portion 71 than to said other major face and which is abuttable against said other interior wall surface.