Connector Terminal Segmentation to Eliminate Molding Burrs
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Solution Overview
Problem
Existing charging connectors often suffer from insufficient molding and burr phenomena in the bending area of the terminal, affecting appearance and functionality.
Innovation Solution
A connector design featuring a terminal with a connecting piece and contact piece, where the connecting portion is fixed on the back of the contact piece via welding, and the entire assembly is embedded in an insulated block with a groove, allowing the connecting pin to pass through for connection to a circuit board, while electroplating enhances the surface finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connecting pin is formed by stamping and bending, then the terminal can be manufactured, but insufficient molding and burr phenomenon occur in the bending area affecting appearance and functionality
Solution Approach 1:
The terminal is divided into separate components: a contact piece and a connecting piece. The connecting piece includes a connecting portion and a connecting pin that are formed separately by stamping, then assembled together. This segmentation allows each component to be manufactured with optimized processes, avoiding the molding defects that occur when forming a single integrated piece through stamping and bending.
2Device complexity
If the connecting pin is formed by stamping and bending, then the terminal structure can be created, but the appearance requirements cannot be met due to burr phenomenon
Solution Approach 1:
By segmenting the terminal into a contact piece and a connecting piece that are assembled together, the design achieves the required structural complexity without the appearance defects. The connecting portion is designed to be received within the insulated block, hiding any potential burrs or imperfections from view.
Solution Approach 2:
The connecting portion of the connecting piece is nested within the insulated block, which is received in the shell assembly. This nesting arrangement conceals the connecting portion and any potential manufacturing imperfections, ensuring that the external appearance meets quality requirements while maintaining the necessary structural complexity.
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 solution ensures a pleasing appearance and eliminates the issues of insufficient molding and burr phenomena, providing a reliable and aesthetically appealing connector with improved manufacturing efficiency and reduced material waste.
Implementation Method 1
the connecting portion is fixed on the back of the contact piece by welding
Implementation Method 2
electroplating is performed on the surface of the terminal
Data Source
AI summary
A connector is provided. The connector includes a shell assembly, a circuit board, a terminal, and an insulated block. The terminal includes a contact piece and a connecting piece including a connecting portion and a connecting pin, and an angle is between the connecting portion and the connecting pin. The insulated block is disposed on one side of the shell assembly, and the connecting pin passes through the insulated block to be connected to the circuit board. The connecting portion and a bending portion of the connecting piece are both embedded in the insulated block. The periphery of the contact piece is devoid of material receiving areas. The contact area of the contact piece has a pleasing appearance. Moreover, as the bending portion is completely embedded in the insulated block, insufficient molding and burr phenomenon during molding can be avoided.