Embedded Terminal Module Assembly for Uniform Pin Height

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Solution Overview

Problem

Conventional connectors face issues with assembly tolerances and structural strength due to deformation or tolerance differences between terminal and plastic components, leading to poor connections when assembled on circuit boards.

Innovation Solution

An embedded terminal module and manufacturing method where a metal terminal element is partially covered by an embedded element during molding, allowing for mirror-aligned assembly in a mating socket, with a removable positioning portion to ensure each pin element maintains consistent height and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If terminal elements are directly inserted into plastic members, then assembly process is simple, but assembly tolerances increase and structural strength decreases

Engineering Contradiction:

Improveassembly process simplicityVSAvoidassembly tolerance

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent merges the terminal element and embedded element into a single integrated component through co-molding. The terminal element is partially covered by the embedded element during the molding process, creating a unified structure that eliminates assembly tolerances between separate parts while maintaining manufacturing efficiency.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses composite materials by combining different materials (metal terminal element and plastic embedded element) into a single integrated component. This composite structure provides both the electrical conductivity of metal and the structural support of plastic, while eliminating interface tolerances between separate components.

Inventive Principle:

Principle #40Composite materials

2Device complexity

If terminal elements are directly inserted into plastic members, then device structure is simple, but structural strength is insufficient

Engineering Contradiction:

Improvedevice structureVSAvoidstructural strength

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The patent combines the terminal element and embedded element into a single integrated component that provides enhanced structural strength. The embedded element partially covers the terminal element, creating a reinforced structure that maintains electrical functionality while significantly improving mechanical strength and resistance to deformation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs composite materials consisting of a metal terminal element partially covered by a plastic embedded element. This composite structure leverages the high strength-to-weight ratio of metal for electrical contacts while using the plastic material to provide structural reinforcement and protection, resulting in a component with superior overall strength.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If plastic components deform or generate tolerance during assembly, then manufacturing is easier, but terminal height uniformity deteriorates

Engineering Contradiction:

Improveassembly easeVSAvoidterminal height uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-positioning the terminal element within the embedded element during the molding process. The terminal element is placed in the mold at a predetermined position before the embedded element is molded around it, ensuring that the terminal height is precisely controlled relative to the embedded element's reference surface, eliminating height uniformity issues that would arise from post-assembly adjustments.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent merges the positioning function into the molding process itself. By co-molding the terminal element and embedded element together, the position relationship is established during manufacturing rather than through subsequent assembly operations. This eliminates the tolerance accumulation that occurs when separate components are assembled, ensuring uniform terminal heights.

Inventive Principle:

Principle #5Merging (Combining)

4Productivity

If conventional connector assembly is used, then production speed is fast, but connection reliability deteriorates

Engineering Contradiction:

Improveproduction speedVSAvoidconnection reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent implements preliminary action by pre-assembling the terminal element and embedded element into an integrated unit during the molding process. This integrated unit is then assembled as a single component into the connector housing, reducing the number of assembly steps while ensuring precise positioning and reliable connections. The preliminary positioning during molding guarantees connection reliability without sacrificing production speed.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12034242B2Embedded terminal module and connector and manufacturing and assembling method thereof

Publication Date: 2024.07.09 WANG CHIA HSIN

AI summary

A method of manufacturing and assembling an embedded terminal module, comprising the steps of: (A) placing a terminal component in a mold; (B) a mating component partially over the terminal component to form a mating terminal component; (C) assembling at least two mating terminal component in a mirror-aligned manner to a mating socket to form the embedded terminal module.