Bidirectional Terminal Insertion Layout for Electrical Connectors
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Solution Overview
Problem
Existing electrical connectors face inefficiencies in terminal installation due to the need to install all terminals from top to bottom, leading to increased wear and tear of the plastic mold assembly.
Innovation Solution
The electrical connector design features an insulating housing with terminals arranged in alternating rows, allowing installation from both the first and second faces, facilitated by guide ribs and strip connecting ribs, enabling efficient installation and reducing wear on the mold assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If all terminals are installed from top to bottom into the terminal slots, then the installation process is simple and uniform, but the installation efficiency is low and the wear and tear of the plastic mold assembly is increased
Solution Approach 1:
The terminal array is segmented into two groups: first terminals installed through the first face and second terminals installed through the second face. This segmentation allows parallel installation processes to occur simultaneously from both faces, doubling the installation throughput while maintaining process simplicity within each face.
Solution Approach 2:
The installation process transitions from a single-direction (top-to-bottom) approach to a bidirectional approach by utilizing both the first face and second face of the insulating housing. This dimensional change enables simultaneous installation operations from opposite directions, significantly improving productivity.
2Ease of manufacture
If all terminals are installed from top to bottom into the terminal slots, then the installation process is straightforward, but the wear and tear of the plastic mold assembly is increased
Solution Approach 1:
The mold assembly is functionally segmented into two independent sets: a first mold for installing first terminals through the first face, and a second mold for installing second terminals through the second face. This segmentation distributes the mechanical wear across two molds instead of concentrating it on one, effectively extending the overall service life of the molding system.
Solution Approach 2:
Instead of installing all terminals from a single face (conventional approach), the invention inverts the approach by installing terminals from both faces simultaneously. This reversal of the conventional single-direction installation method reduces the cumulative wear on any single mold assembly.
3Productivity
If terminals are arranged in alternating first terminals and second terminals, then installation efficiency is improved and mold wear is reduced, but the device structure becomes more complex
Solution Approach 1:
The terminal array employs an asymmetric arrangement where first terminals and second terminals are positioned in alternating fashion and inserted from opposite faces. This asymmetric configuration optimizes the installation process by allowing parallel processing while maintaining electrical functionality, achieving improved productivity without excessive complexity.
Solution Approach 2:
Both first terminals and second terminals share the same basic structure and insertion mechanism, but are adapted for insertion from different faces. This universal design approach allows the same terminal type to serve multiple functions (insertion from first face or second face), reducing the overall complexity compared to having completely different terminal designs.
Data Source
AI summary
An electrical connector includes: an insulating housing having opposite first and second faces and a plurality of accommodation and fixing slots; and at least one row of terminals arranged in a first direction and extending forward along a second direction, each terminal having: a base portion fixed in one of the fixing slots; a first resilient arm protruding from the first face; and a second resilient arm protruding from the second face, wherein the at least one row of terminals includes first terminals and second terminals alternately arranged, the base portions of the first terminals are inserted from the first face into corresponding fixing slots, and the base portions of the second terminals are inserted from the second face into corresponding fixing slots.