Electrical Connector Terminals Simplified Assembly
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Solution Overview
Problem
The existing electrical connectors require separate assembly procedures for signal and power terminals due to structural differences, leading to increased operation time and manufacturing costs as they cannot be set on the same carrier tape.
Innovation Solution
The design includes an insulative housing with first and second passageways for terminals of the same length, where the second passageway's leg section has a transition section and tailing section positioned closer to the mating face, allowing both types of terminals to be set on a common carrier tape for simultaneous assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If signal terminals and power terminals are assembled separately due to structural differences, then reliable electrical connection is achieved, but assembly operation time and manufacturing costs increase
Solution Approach 1:
The patent changes the geometric parameters of the received sections by providing different extension distances from the mating face. Power terminal received sections extend a first distance while signal terminal received sections extend a second distance, allowing both terminal types to be accommodated in the same carrier tape while maintaining their respective electrical connection requirements
Solution Approach 2:
The insulative housing is segmented into different regions with distinct passageway configurations. First passageways accommodate signal terminals while second passageways accommodate power terminals, allowing simultaneous assembly from the same carrier tape while maintaining separate assembly paths for each terminal type
2Reliability
If power terminal received section is extended closer to mating face, then reliable power connection is achieved, but terminal structural complexity increases
Solution Approach 1:
The patent modifies the extension distance parameter of the received section for power terminals to extend closer to the mating face compared to signal terminals. This parameter change ensures reliable power connection while maintaining a relatively simple structural form without adding complex features
3Reliability
If different received section configurations are used for signal and power terminals, then reliable electrical engagement is achieved, but manufacturing costs increase
Solution Approach 1:
The patent achieves different received section configurations by changing only the extension distance parameter from the mating face, rather than using fundamentally different structural designs. This simplified approach reduces manufacturing complexity and costs while ensuring reliable electrical engagement for both terminal types
Solution Approach 2:
The insulative housing is designed with universal features including a common carrier tape accommodation structure that can hold both signal and power terminals simultaneously. The housing provides multiple passageways with different extension distances, allowing a single housing design to accommodate multiple terminal types with different requirements
Data Source
AI summary
An electrical connector (1) includes an insulative housing (2) defining a mating face (200) thereof. First and second terminals (3, 4) have the same-length received section (30, 40) in the respective passageways, and a leg section (31, 41), wherein the received section (40) of the second terminal (4) extends much closer to the mating face (200) than that of the first terminal (3). The leg section (41) of the second terminal (4) has a transition section (411), and a tailing section (410) located with a same distance away from the mating face (200) with that of the first terminal (3). This configuration of the first terminals (3) and the second terminals (4) can be set on a same carrier tape (6) to be assembled onto the insulative housing (2) in a common working procedure, which will reduce the operation time and manufacturing costs.