Connector Assembly for Narrow Terminal Pitch Manufacturing
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Solution Overview
Problem
Conventional connectors face challenges in producing compact and reliable designs with narrower spacing between terminals due to integrated terminal and housing structures, making it difficult to precisely deploy a large number of terminals in the molding process.
Innovation Solution
The connector design features half body parts with terminals arranged at a predetermined pitch, integrated with a reinforcing metal fitting, and a unique tail part configuration that allows for narrower spacing between protruding parts, facilitating easier production and assembly while maintaining reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If terminals are integrated with the housing using overmolding or insert molding, then the connector becomes more compact with narrower spacing between protruding parts, but the production becomes more difficult due to precision requirements in deploying a large number of terminals in the mold
Solution Approach 1:
The connector is divided into two separate components: the housing (connector main body) and the terminals. The housing is molded without integrated terminals, allowing for easier and more precise manufacturing. The terminals are then separately mounted onto the housing in a subsequent process, eliminating the complexity of integrating numerous terminals directly into the mold while achieving the desired compact spacing between protruding parts.
2Manufacturing precision
If terminals are integrated with the housing, then narrower pitch between terminals is achieved, but precise deployment of a large number of terminals in the molding process becomes difficult
Solution Approach 1:
The manufacturing process is segmented into two distinct stages: first, molding the housing without terminals to ensure structural precision and proper pitch; second, separately mounting the terminals onto the pre-formed housing. This segmentation eliminates the complexity of integrating terminal deployment into the molding process while maintaining precise terminal pitch through controlled separate positioning.
Solution Approach 2:
The housing is prepared in advance with the correct structural form, pitch dimensions, and mounting features before terminals are attached. This preliminary formation of the housing ensures that the pitch between protruding parts is precisely established during molding, and subsequent terminal mounting can focus solely on precise positioning without the added complexity of simultaneous terminal integration.
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 enables the production of compact and reliable connectors with narrower terminal spacing, enhancing the ease of manufacturing and ensuring effective electrical connections.
Implementation Method 1
half body parts, each including a connector main body and a plurality of terminals arranged at a predetermined pitch and integrated with the connector main body by insert molding
Data Source
AI summary
A connector is provided with a half body part, each of which including a connector main body and a plurality of terminals arranged at a predetermined pitch and integrated with the connector main body by insert molding, a main body end part formed at both ends of the connector main body by coupling the connector main bodies of the half body parts arranged in parallel, and a reinforcing metal fitting integrated with the main body end part.