Electrical Connector Vertical Cavities Solderless Assembly

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Solution Overview

Problem

The existing electrical connector technologies face complexity in assembly with circuit boards due to the intricate welding process of conductive terminals, which hinders production efficiency.

Innovation Solution

An electrical connector design featuring an insulative housing with vertically arranged receiving cavities and conductive terminals with upward and downward contact portions, allowing for easy insertion and connection of electrical components without soldering, facilitated by a shielding shell and limiting protrusions for secure fixation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding is used to fix conductive terminals on circuit board, then connection strength is improved, but assembly complexity and production time increase

Engineering Contradiction:

Improveconnection strengthVSAvoidassembly complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent replaces the welding process (thermal/chemical system) with a mechanical insertion system. The conductive terminals are designed with insertion structures that mechanically engage with the circuit board, eliminating the need for welding operations while maintaining connection integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The conductive terminals are pre-configured with insertion structures and positioning features during manufacturing. The circuit board is pre-designed with corresponding receiving cavities and fixing structures. This preliminary preparation enables direct mechanical assembly without requiring complex welding procedures during final assembly.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If welding process is used for assembling conductive terminals, then connection reliability is improved, but production efficiency deteriorates

Engineering Contradiction:

Improveconnection reliabilityVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent substitutes the welding process with a mechanical insertion and fixation mechanism. The conductive terminals feature insertion ends that directly engage with receiving cavities in the circuit board, accompanied by fixing structures (such as clamping or snapping mechanisms) that ensure reliable electrical and mechanical connection without thermal processing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Both the conductive terminals and circuit board are pre-designed with complementary geometric features including insertion cavities, positioning protrusions, and fixing structures. This preliminary configuration allows for rapid, tool-free or minimal-tool assembly, dramatically improving production efficiency while maintaining connection reliability through precise mechanical engagement.

Inventive Principle:

Principle #10Preliminary action

3Strength

If complex welding assembly is used, then connection strength is improved, but manufacturing time increases

Engineering Contradiction:

Improveconnection strengthVSAvoidmanufacturing time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent eliminates the time-consuming welding process by implementing a mechanical insertion system. The conductive terminals are designed with insertion ends that directly fit into receiving cavities in the circuit board, with integrated fixing structures that secure the connection through simple mechanical action, reducing assembly time from minutes per connection to seconds.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The conductive terminals and circuit board are pre-configured with matching geometric features including insertion cavities, positioning structures, and fixing mechanisms during the manufacturing phase. This preliminary preparation enables rapid assembly operations, significantly reducing manufacturing time while ensuring strong, reliable connections through precise mechanical engagement.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS9979113B2Electrical connector and assembly thereof

Publication Date: 2018.05.22 FOXCONN INTERCONNECT TECHNOLOGY LTD

AI summary

An electrical connector comprises an insulative housing extending in a horizontal direction and a plurality of conductive terminals retained in the insulative housing. The electrical connector is provided with a first receiving cavity and a second receiving cavity which are arranged in an up-and-down arrangement in a vertical direction perpendicular to the horizontal direction. Each conductive terminals comprises a first contact portion extending upwardly into the first receiving cavity and a second contact portion extending downwardly into the second receiving cavity. The conductive terminals are used to electrically connect a pair of first and second electrical components which are respectively inserted into the first and second receiving cavity via the first and second contact portions. The electrical connector is provided with the receiving cavity for inserting the second electrical component, thereby facilitating the assembly of the second electrical component and the electrical connector.