Connector Assembly Wedge Actuation for Mating Load Isolation
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Solution Overview
Problem
Existing connector assemblies face issues with relative movement between terminal holders and housing parts, leading to poor electrical contact quality and reliability, especially during mating sequences, and potential damage to solder joints on printed circuit boards.
Innovation Solution
A connector assembly design featuring a terminal holder with flexible legs and wedge portions, coupled with an actuating portion, allows for controlled mounting displacement to prevent relative movement between housing parts, ensuring precise and reliable terminal alignment without rigid fixation means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rigid fixation means (screwing means, locking means) are used to mount the terminal holder in the second housing part, then the terminal holder position is fixed precisely, but the assembly complexity increases and manufacturing cost increases
Solution Approach 1:
The invention extracts the rigid fixation means (screws, locking mechanisms) from the assembly structure and replaces them with a compliant mounting system. The terminal holder is mounted in the second housing part without rigid fixation, allowing controlled movement through a defined path, thereby simplifying the assembly structure while maintaining positioning precision through the guided movement mechanism.
Solution Approach 2:
The invention transforms the static rigid fixation system into a dynamic compliant mounting system. The terminal holder is allowed to move along a defined path in response to assembly tolerances and thermal expansion, converting the rigid constraint into a controlled dynamic adjustment that maintains electrical contact quality without requiring complex locking mechanisms.
2Reliability
If rigid fixation means are used to mount the terminal holder, then relative movement is prevented, but the stress on soldering area increases during mating sequence
Solution Approach 1:
The compliant mounting system allows the terminal holder to move along a defined path during the mating sequence, dynamically absorbing the loads generated during connector engagement. This prevents the transmission of mating loads to the soldering area, protecting the solder joints while maintaining reliable electrical contact through the controlled movement mechanism.
Solution Approach 2:
The invention implements a cushioning mechanism by allowing the terminal holder to move along a defined path before the mating loads are fully transmitted. This pre-compliance absorbs the shock and stress of the mating sequence, protecting the solder joints from excessive forces while ensuring that electrical contact is established reliably.
3Productivity
If separate assembly lines are used for terminals, printed circuit board, and connector assembly, then manufacturing flexibility is improved, but relative movement between components occurs due to accumulated tolerances
Solution Approach 1:
The invention implements a compliant mounting system that allows the terminal holder to move along a defined path, dynamically compensating for accumulated tolerances from separate assembly lines. This enables different suppliers and assembly lines to produce components with standard tolerances while the final assembly achieves precise alignment through the controlled movement mechanism.
Solution Approach 2:
The invention changes the mounting parameters from rigid fixed positions to controlled movable positions along a defined path. This parameter change allows the system to adapt to variations in component dimensions from different assembly lines, maintaining precise alignment without requiring tight tolerances in the individual components manufactured by different suppliers.
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
The solution enhances electrical contact reliability and reduces movement-induced stress on solder joints, providing cost-effective and robust assembly with improved positioning accuracy and reduced manufacturing complexity.
Implementation Method 1
The second housing part comprises an actuating portion and the terminal holder comprises a wedge portion, the wedge portion being configured to be at least partially inserted between the first housing part and the terminal holder. The actuating portion is configured to press on the wedge portion when the second housing part is mounted with the first housing part, along the mounting displacement.
Data Source
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AI summary
A connector assembly comprising a connector comprising a first housing part (1), a second housing part and a terminal holder (3) accommodated in the first housing part (1). The second housing part comprises an actuating portion (25) and the terminal holder (3) comprises a wedge portion (14), the wedge portion (14) being configured to be at least partially inserted between the first housing part (1) and the terminal holder (3). The actuating portion (25) is configured to press on the wedge portion (14) when the second housing part is mounted with the first housing part (1). The terminal holder (3) and the wedge portion (14) are configured to block a movement parallel to the mating direction (MD) between the first housing part (1) and the terminal holder (3) when the wedge portion (14) is pushed by the actuating portion (25).