Electrical Connector Terminal Module Retention
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Solution Overview
Problem
Existing electrical connectors with insulating housings face challenges in efficiently and securely retaining a large quantity of terminal modules, leading to prolonged assembly times and potential loosening of terminals.
Innovation Solution
The electrical connector design includes terminal modules with insulators and through holes, where the insulating housing is overmolded to fill these holes, enhancing retention through injection molding, and recessed holes are used to improve the connection between terminal modules and the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If terminals are retained in the insulating housing by interference fit, then the terminals can be assembled into the housing, but the assembling process takes a lot of time and the terminals may become loose from the housing
Solution Approach 1:
The invention divides the connector into modular terminal modules, where each module contains multiple terminals pre-assembled on an insulator. This segmentation allows the entire module to be inserted as one unit rather than assembling individual terminals, dramatically improving assembly efficiency while maintaining retention stability through the module's integrated structure.
Solution Approach 2:
The invention merges multiple terminals with the insulator to form an integrated terminal module. The insulator combines with terminals through molding to create a unified structure that is then retained as a single unit in the housing, eliminating the need for individual terminal assembly and improving both efficiency and reliability.
2Quantity of substance
If a large quantity of terminals are assembled into the housing, then the connector can accommodate more connections, but the assembling process takes a lot of time
Solution Approach 1:
By segmenting terminals into modular groups (terminal modules), the invention enables batch assembly of multiple terminals simultaneously. Each module containing multiple terminals is assembled as one unit, reducing the total assembly time proportionally to the number of terminals per module while maintaining the capability to accommodate large quantities of connections.
Solution Approach 2:
The invention performs preliminary assembly of terminals onto insulators to create pre-assembled terminal modules before final installation into the housing. This preliminary action of grouping terminals into modules beforehand eliminates repeated assembly operations and significantly reduces the time required to install large quantities of terminals.
3Strength
If terminals are retained by interference fit, then the terminals can be held in the housing, but the terminals may become loose from the insulating housing
Solution Approach 1:
The insulator merges with terminals through molding to form an integrated terminal module structure. This merging creates a unified assembly where terminals are permanently fixed to the insulator, eliminating the risk of terminals becoming loose from the housing while maintaining strong retention through the module's integrated design.
Solution Approach 2:
The insulator acts as an intermediary between terminals and the housing. Terminals are firmly attached to the insulator through molding, and the insulator module is then retained in the housing, providing stable retention while preventing direct contact between terminals and housing that could lead to loosening.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design significantly reduces assembly time and ensures secure retention of terminal modules, preventing loosening and improving the overall reliability and efficiency of the connector.
Implementation Method 1
an insulating housing overmolding and retaining the plurality of terminal modules to define a mating cavity, wherein the insulator of each terminal module defines a plurality of through holes miming therethrough in the second direction, and materials of the insulating housing fill the through holes of each terminal module
Data Source
AI summary
An electrical connector includes: plural terminal modules each including a row of terminals arranged in a first direction and an insulator molded with the row of terminals, the plural terminal modules being arranged in a second direction perpendicular to the first direction; and an insulating housing overmolding and retaining the plurality of terminal modules to define a mating cavity, wherein the insulator of each terminal module defines plural through holes running therethrough in the second direction, and materials of the insulating housing fill the through holes of each terminal module.