Connector Unit Terminal Block Guide Rail Suspension
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Solution Overview
Problem
The existing connector units face increased component and manufacturing costs due to the need for screws to fix terminal blocks to boards, leading to stress concentration at soldering points, which can result in defects under vibration, and require complex assembly processes.
Innovation Solution
A connector unit design featuring a terminal block with a flange supported by a guide rail within the housing, allowing the board to be suspended through the terminal, eliminating direct fixation and thus reducing stress concentration at soldering points, and incorporating a positioning protrusion and leg piece for accurate alignment and stabilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the terminal block is directly fixed to the board using screws, then the terminal block positioning stability is improved, but the component cost and manufacturing complexity increase
Solution Approach 1:
The patent removes the screws from the system entirely. Instead of directly fixing the terminal block to the board with screws, the terminal block is suspended through the terminal itself, which is inserted into a through-hole of the board and soldered. This extraction of the screw component simplifies the manufacturing process while maintaining positioning stability through the soldered terminal connection.
Solution Approach 2:
The terminal acts as an intermediary element between the terminal block and the board. Rather than using screws to directly connect the terminal block to the board, the terminal serves as the mediating component that transmits both electrical signals and mechanical positioning forces, eliminating the need for separate fastening hardware.
2Manufacturing precision
If the terminal block is directly fixed to the board, then the positioning accuracy is improved, but stress concentrates on the soldering place causing potential defects
Solution Approach 1:
The patent segments the fixing function from the soldering function. The terminal block's positioning is achieved through the terminal's insertion into the board's through-hole and subsequent soldering, while the terminal block itself is supported by a guide rail in the housing. This segmentation distributes stress away from the soldering location, preventing stress concentration that could cause defects.
Solution Approach 2:
The guide rail serves as an intermediary support structure that bears the mechanical load of the terminal block, preventing this stress from being transmitted to the soldered terminal connection. The guide rail mediates between the housing and the terminal block, providing structural support while preserving the integrity of the electrical connection.
3Strength
If screws are used to fix the terminal block to the board, then the fixation strength is improved, but the component cost increases
Solution Approach 1:
The patent extracts screws from the component list entirely. The fixation strength previously provided by screws is replaced by the combined mechanism of the terminal's soldered connection to the board and the guide rail's support within the housing. This eliminates the need for additional fastening components, reducing part quantity and cost.
Solution Approach 2:
The terminal serves a dual function: it provides both the electrical connection and the mechanical positioning/fixation. By making the terminal self-sufficient for both functions, the patent eliminates the need for separate fixation components like screws, thereby reducing component quantity while maintaining adequate fixation strength through the soldered joint and guide rail support.
Data Source
AI summary
A connector unit includes: a housing including a guide rail inside the housing; a terminal block including a flange and configured to hold a terminal having one end exposed in an opening of the housing, the terminal block being housed inside the housing with the flange supported by the guide rail; and a board connected with the other end of the terminal and housed in the housing with the board suspended from the terminal block through the terminal.