Electrical Connector Terminal Structure for High-Density Assembly
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Solution Overview
Problem
Existing electrical connectors face challenges in achieving higher terminal density and high-frequency characteristics due to the width of terminals and the need for pre-breaking strip connecting portions, which leads to terminals easily falling during electroplating and transferring processes.
Innovation Solution
The design includes an insulating body with vertically running accommodating slots and terminals featuring a first elastic arm, a separation that divides the arm into sub-arms, and a second elastic arm, allowing for a narrower terminal width and assembly without pre-breaking, using a jig to assemble the terminals into slots, thus enhancing terminal density and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the upper ends of the left and right sides of the base portion both extend upward to form strip connecting portions, then the terminal can be connected to a strip, but the width of the terminal in the left-right direction becomes greater, resulting in larger terminal volume which is not suitable for high terminal density
Solution Approach 1:
The base portion is divided into two separate strip connecting portions located at different positions, allowing the terminal to connect to strips without requiring both left and right sides to extend upward, thereby reducing terminal width and volume while maintaining strip connection capability
Solution Approach 2:
The strip connecting portions are positioned at different heights relative to the base portion, with one extending upward and the other extending sideways or downward, utilizing vertical and lateral dimensions differently to reduce the left-right width of the terminal
2Ease of manufacture
If pre-breaking is performed at the strip connecting portions during terminal assembly, then the terminals can be connected to strips, but the terminals easily fall from the strip in the electroplating and transferring processes
Solution Approach 1:
The strip connecting portions are designed with pre-formed bending structures and positioning features that enable direct connection to strips without requiring pre-breaking operations, eliminating the source of instability while maintaining ease of assembly
Solution Approach 2:
The structural parameters of the strip connecting portions are optimized, including their length, position, and bending radius, to provide sufficient connection strength and stability during electroplating and transferring processes without requiring pre-breaking
3Ease of manufacture
If the terminal width is increased to accommodate strip connecting portions on both sides, then strip connection is enabled, but the terminal density of the electrical connector decreases
Solution Approach 1:
The strip connecting functionality is segmented into two separate portions positioned at different locations and orientations, allowing one to extend minimally while the other provides the primary connection, thus reducing overall terminal width and increasing terminal density
Solution Approach 2:
Different regions of the terminal are designed with different properties: one strip connecting portion is designed to be compact and integrated into the base portion, while the other is positioned to provide connection functionality without increasing the overall terminal width, optimizing local space utilization
Data Source
AI summary
An electrical connector includes an insulating body having accommodating slots and terminals accommodated in the accommodated slots. Each terminal has a body portion, a first elastic arm, a separation provided on the first elastic arm and the body portion, and a second elastic arm having at least one end integrally connected to a corresponding end of the separation. A left side edge or a right side edge of the body portion has a strip connecting edge to be connected to a strip. Each of left and right side edges of the separation has a first edge and a second edge located below the first edge. The second edge protrudes inward toward the separation relative to the first edge, such that the upper end of the body portion forms an abutting region for a jig to abut against each terminal to be assembled downward in a corresponding accommodating slot.