Electrical Connector Terminal Density and Mold Simplification
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Solution Overview
Problem
Existing electrical connectors face challenges in densely arranging terminals without short-circuiting, and the insert-molding process is complicated due to the design of connecting and wing portions, leading to safety concerns.
Innovation Solution
An electrical connector design featuring an insulating body with through holes and protruding portions, along with terminals and a conductive plate formed from a metal plate, where each terminal has a base portion and an elastic arm, and cutting slots are strategically formed to allow for dense arrangement and prevent short-circuiting by ensuring clean cutting of connecting portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the connecting portion and wing portions are located in separate openings (first openings and second openings), then the terminals can be arranged densely, but the insert-molding process becomes complicated requiring multiple engaging members
Solution Approach 1:
The patent merges the connecting portion and wing portion into a single integrated terminal structure that occupies one opening rather than requiring separate openings. This integration allows the terminal to be molded using a single engaging member in the mold, significantly simplifying the mold structure while maintaining high terminal density in the connector
2Productivity
If the connecting portion is cut during manufacturing, then the terminals can be separated, but there is no guarantee of complete cutting which may result in short-circuiting
Solution Approach 1:
The patent extracts the connecting portion from the terminal structure by providing a dedicated cutting slot that completely separates it. The cutting slot is designed to extend through the entire thickness of the terminal, ensuring complete separation. The insulating body is also configured to expose the cutting slot, allowing visual verification that the cut is complete, thereby guaranteeing no short-circuiting while maintaining manufacturing efficiency
3Ease of manufacture
If multiple engaging members are used to cover the upper and lower surfaces of the wing portions and connecting portion, then the insert-molding can be completed, but the forming process becomes complicated
Solution Approach 1:
The patent combines the functions of multiple engaging members into a single engaging member by integrating the connecting portion and wing portion into one terminal structure. The single engaging member simultaneously supports and molds both the connecting portion and wing portion, dramatically reducing mold complexity while ensuring complete insert-molding of all terminal components
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
The design enables a denser arrangement of terminals while preventing short-circuiting and simplifies the insert-molding process by allowing clear observation of cutting accuracy, thus enhancing safety and manufacturing efficiency.
Implementation Method 1
each of the terminals has a base portion and an elastic arm integrally connected to the base portion, the elastic arm bends upward
Data Source
AI summary
An electrical connector includes multiple terminals formed by cutting from a metal plate and bending. The portion of the metal plate with the terminals being removed is defined as a base plate. Each terminal has a base portion and an elastic arm connected thereto. The base portion is at least partially horizontally provided to be coplanar to the base plate. A cutting slot is formed between the base plate and the base portion. A through slot is formed between the base plate and the elastic arm. An insulating body is provided with through holes running vertically therethrough. A portion of the cutting slot and the through slot are exposed in a corresponding through hole. The terminals include signal terminals and ground terminals. The base plate forms a connecting portion between the through slot and the cutting slot of each ground terminal to be connected to the ground terminal.