Electrical Connector Terminals at Different Heights
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrical connectors with terminals at different heights face challenges in maintaining co-planarity due to thermal deformation during reflow soldering, leading to unevenness and potential soldering defects.
Innovation Solution
The electrical connector design includes a housing with vertical walls and recessed portions between terminals, where the first terminal is press-fitted with pressure on two sides in the width direction and the second terminal is press-fitted with pressure on two sides in both width and height directions, which helps maintain the inclination of the walls and reduces the risk of uneven displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a recessed portion is provided to remove or thin-out a portion of the housing between the press fitting portions, then the housing structure is optimized for manufacturing and assembly, but the co-planarity between the leg portions of the terminals deteriorates due to differential thermal deformation
Solution Approach 1:
The patent applies local quality by providing different press fitting configurations to different terminals based on their specific positions and deformation characteristics. The first terminal is press-fitted only in the width direction, while the second terminal is press-fitted in both width and height directions, allowing each terminal to be optimized for its local thermal deformation behavior while maintaining overall co-planarity
Solution Approach 2:
The patent changes the press fitting parameters (directions and constraints) for different terminals to compensate for differential thermal deformation. By adjusting the press fitting constraints based on the specific position and deformation tendency of each terminal, the invention maintains co-planarity despite the recessed portion causing different thermal deformation characteristics
2Strength
If the first terminal is press-fitted with pressure on two sides in the width direction only, then the terminal is securely retained in the housing, but the wall inclination is not controlled, leading to potential displacement during soldering
Solution Approach 1:
The patent applies local quality by providing different press fitting configurations to different terminals based on their specific positions and deformation characteristics. The first terminal is press-fitted only in the width direction, while the second terminal is press-fitted in both width and height directions, allowing each terminal to be optimized for its local thermal deformation behavior while maintaining overall co-planarity
Solution Approach 2:
The patent applies preliminary action by pre-controlling the wall inclination through selective press fitting before the thermal deformation occurs during soldering. The press fitting in the height direction for the second terminal pre-compensates for the expected thermal deformation, ensuring that the terminal maintains proper position and co-planarity even after heating
3Manufacturing precision
If the second terminal is press-fitted with pressure on two sides in both width and height directions, then the wall inclination is controlled and co-planarity is maintained, but the press fitting process becomes more complex
Solution Approach 1:
The patent applies local quality by providing different press fitting configurations to different terminals based on their specific positions and deformation characteristics. The first terminal is press-fitted only in the width direction, while the second terminal is press-fitted in both width and height directions, allowing each terminal to be optimized for its local thermal deformation behavior while maintaining overall co-planarity
Solution Approach 2:
The patent applies partial action by providing press fitting constraints only where needed. The first terminal requires only width direction press fitting, while the second terminal (which has different deformation characteristics due to the recessed portion) requires additional height direction press fitting. This partial application of constraints maintains co-planarity without unnecessarily complicating the press fitting process for all terminals
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 configuration ensures favorable co-planarity between the terminals and reduces the risk of soldering defects by controlling the inclination of the walls and maintaining a stable gap between the terminals and the mounting surface.
Implementation Method 1
the first press-fitting portion is press-fitted into the vertical wall by coming into pressure contact with, among wall surfaces that constitute the first hole in the vertical wall, wall surfaces on two sides in a width direction
Implementation Method 2
the second press-fitting portion is press-fitted into the vertical wall by coming into pressure contact with, among wall surfaces that constitute the second hole in the vertical wall, wall surfaces on two sides in the width direction and wall surfaces on two sides in the height direction
Implementation Method 3
the electrical connector undergoes deformation due to heat from the reflow soldering apparatus
Implementation Method 4
the leg portion of the terminal of the electrical connector is soldered to the mounting target member by reflow soldering
Data Source
AI summary
An electrical connector having terminals at different heights includes: a housing having a vertical wall provided with a first hole and a second hole on the counter mating side thereof; a first terminal press-fitted into the first hole; and a second terminal press-fitted into the second hole. A recessed portion is provided between the first hole and the second hole in the vertical wall. A first press-fitting portion is press-fitted into the vertical wall by coming into pressure contact with, among the wall surfaces constituting the first hole in the vertical wall, the wall surfaces on the two width direction sides, and a second press-fitting portion is press-fitted into the vertical wall by coming into pressure contact with, among the wall surfaces constituting the second hole in the vertical wall, the wall surfaces on the two width direction sides and the wall surfaces on the two height direction sides.