Board-to-Board Connector Terminals Using 180° Inversion

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Solution Overview

Problem

Existing board-to-board connectors require different manufacturing molds for male and female terminals, leading to increased manufacturing costs due to non-identical terminal designs.

Innovation Solution

The connector assembly features first and second connectors with identical terminal mating portions that are inverted 180 degrees relative to each other, allowing for the use of the same stamping die and reducing manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If different terminal designs are used for male and female connectors, then effective electrical connection is achieved, but manufacturing cost increases due to requiring different manufacturing molds

Engineering Contradiction:

Improveelectrical connectionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies inversion by making the male and female terminal mating portions identical in structure but inverted 180 degrees relative to each other. Instead of designing completely different terminal structures for male and female connectors, the invention uses the same terminal design with opposite orientations, allowing both to be manufactured using the same mold while still achieving effective electrical connection when mated.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent implements universality by designing a universal terminal structure that can serve both male and female connector functions. The same terminal design is used for both connectors, with the only difference being the 180-degree inversion in orientation. This universal design allows a single manufacturing mold to produce terminals for both male and female connectors, reducing manufacturing complexity and cost.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If identical terminal designs are used for male and female connectors, then manufacturing cost is reduced, but the terminals must be inverted 180 degrees relative to each other

Engineering Contradiction:

Improvemanufacturing costVSAvoidterminal orientation

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The patent applies asymmetry in a controlled manner by introducing 180-degree rotational inversion as the only asymmetric difference between male and female terminals. The terminal structures themselves are identical (symmetric in design), but their orientations are asymmetrically inverted to accommodate their respective roles in male and female connectors, enabling both manufacturing simplicity and functional differentiation.

Inventive Principle:

Principle #4Asymmetry

Data Source

PatentUS20230411891A1Connector Assembly

Publication Date: 2023.12.21 TYCO ELECTRONICS (SHANGHAI) CO LTD

AI summary

A connector assembly has a first connector and a second connector. The first connector includes a first housing and a first terminal arranged in the first housing. The first terminal includes a first terminal mating portion. The second connector includes a second housing and a second terminal arranged in the second housing. The second terminal includes a second terminal mating portion that corresponds to the first terminal mating portion. The first terminal mating portion is identical to the second terminal mating portion but is inverted 180 degrees relative to the second terminal mating portion.