Electrical Connector Terminal Isolation and Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The increasing number of terminals in smaller electrical connectors, such as USB C type connectors, leads to reduced structural strength and assembly challenges due to narrower terminal widths and larger terminal counts, resulting in higher defect rates and potential misalignment during assembly.
Innovation Solution
The electrical connector design includes a casing, insulative base with complex structures, internal and external conductive sheets, and a block with notches, which isolate terminals to prevent signal interference and enhance assembly yield through specific assembly methods like Insert-Molding, and positioning protrusions for secure alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of terminals increases and terminal width is narrowed to fit more terminals in smaller space, then the transmission specifications are upgraded, but the structural strength of terminals and insulative base reduces
Solution Approach 1:
The insulative base is divided into multiple complexes (first complex, second complex, third complex) that are sequentially connected. Each complex can independently support terminals, distributing the mechanical load and maintaining structural strength even as the total number of terminals increases.
Solution Approach 2:
Different regions of the insulative base are designed with different structural characteristics. The complexes have varying configurations to optimize local strength where needed, allowing the overall structure to maintain integrity while accommodating narrow terminals throughout.
2Quantity of substance
If the number of terminals increases and terminal width is narrowed, then more terminals can be disposed in smaller space, but assembly precision decreases due to difficulties in visual determination
Solution Approach 1:
The patent employs visual differentiation through color or appearance variations in the conductive sheets and terminal structures. This allows operators to easily distinguish between different terminal types and positions, maintaining high assembly precision even when terminals are narrow and densely packed.
Solution Approach 2:
The conductive sheets serve as intermediary components that provide visual references and physical guides during assembly. These sheets help operators accurately position terminals by providing clear visual boundaries and alignment features, compensating for the difficulty of visually determining precise terminal positions.
3Area of stationary object
If terminals are narrowed in width to increase terminal count, then space utilization improves, but terminal strength becomes weaker leading to bend or curve during assembly
Solution Approach 1:
The conductive sheets are pre-positioned and fixed to the insulative base before terminal installation. This preliminary action provides pre-established support structures that prevent terminals from bending or curving during the assembly process, compensating for the reduced inherent strength of narrow terminals.
Solution Approach 2:
The conductive sheets act as intermediary support structures between the insulative base and the narrow terminals. They provide additional mechanical reinforcement to the terminals during assembly, preventing deformation while allowing the terminals to maintain their narrow width for high-density configuration.
4Quantity of substance
If the number of terminals increases, then transmission capabilities are enhanced, but defect rate increases due to higher difficulty in determining proper assembly
Solution Approach 1:
Visual differentiation through color or appearance variations in the conductive sheets and terminal structures enables easy identification of properly assembled terminals. This visual feedback mechanism reduces defects by allowing operators to quickly verify assembly correctness even when dealing with large numbers of narrow terminals.
Solution Approach 2:
The conductive sheets serve as intermediary reference structures that provide clear visual and physical guides for proper terminal positioning. These sheets reduce assembly errors by making correct assembly positions easily identifiable, thereby lowering the defect rate despite the increased complexity of high-terminal-count configurations.
Data Source
AI summary
An electrical connector comprises an external conductive sheet, an upper internal conductive sheet, a lower internal conductive sheet and the necessary others. An insulative base is disposed within a casing and includes a top complex, a center complex, and a bottom complex in sequential connection. The upper internal conductive sheet and the lower internal conductive sheet are fixed to the insulative base. Thereafter, an improving electrical connector interface is provided.