Electrical Connector Terminal Module Vertical Assembly
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Solution Overview
Problem
Existing electrical connectors face difficulties in assembling terminal modules along vertical directions due to the orientation of mounting and contacting portions, making it challenging to retain terminals in insert molding machines.
Innovation Solution
The electrical connector design includes a second terminal module with a second insulator featuring a vertical and horizontal portion, separated by bending portions formed through a pressing process after insert molding, allowing easy retention and assembly along a single horizontal direction, enabling vertical assembly of the second terminal module with the first module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the mounting portions are disposed vertically to mount to an exterior board through a through-hole manner, then the mounting can be achieved, but it is difficult to retain the terminals to the insert molding machine along two vertical directions
Solution Approach 1:
The patent changes the orientation relationship between mounting portions and contacting portions from vertical (requiring two-directional retention) to parallel horizontal arrangement (requiring only one-directional retention). This dimensional reorientation allows terminals to be retained in the insert molding machine along a single horizontal direction while still achieving vertical mounting capability through the exterior board.
2Ease of manufacture
If the mounting portions are disposed parallel to the contacting portions, then the terminals can be easily retained to an insert molding machine along one direction, but the vertical assembly capability is limited
Solution Approach 1:
The patent introduces a pressing process that dynamically changes the orientation of the mounting portions from parallel to vertical relative to the contacting portions. This dynamic reconfiguration after insert molding enables the terminals to achieve vertical assembly capability with the exterior board while having benefited from the simplified one-directional retention during the molding process.
Data Source
AI summary
An electrical connector comprises a first terminal module, a second module and a shell. The first terminal module has a first insulator and a plurality of first terminals embedded in the first insulator. The first insulator has a first vertical portion, a first horizontal portion and a first tongue plate. The second terminal module has a second insulator and a plurality of second terminals embedded in the second insulator. The second insulator has a second vertical portion, a second horizontal portion and a second tongue plate. The second vertical portion and the second horizontal portion are separated from each other, and the second terminal connects the second vertical portion with the second horizontal portion.