Fine Pitch Electrical Connector via Insert-Molded Contact Modules
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Solution Overview
Problem
Existing electrical connectors with fine pitch contact arrangements face challenges in miniaturization due to the side arms of the conducting portion, which prevent neighboring contacts from being densely arranged, hindering the miniaturization of the connector.
Innovation Solution
The electrical connector features insulative housing with contact modules where contacts are integrally formed within an insulator, with opposite contacting arms and a holding tab, allowing for insert-molding and subsequent assembly into the housing using a gripping tool, enabling a fine pitch arrangement by removing linking sections between neighboring contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If side arms of the conducting portion are used to connect neighboring contacts, then the contacts can be arranged in a grid pattern for structural stability, but the pitch between contacts increases and miniaturization is prevented
Solution Approach 1:
The patent removes the linking sections between neighboring contacts after insert-molding, extracting the connecting function from the contact structure itself. This allows contacts to be densely arranged without the space requirements of side arms, achieving fine pitch arrangement while maintaining structural integrity through the insulator housing.
Solution Approach 2:
The patent divides the contact assembly into modular contact modules, each containing multiple contacts that are integrally formed within an insulator. These modules can be independently manufactured and assembled, allowing for optimized pitch arrangements without the constraint of continuous side arms spanning across all contacts.
2Productivity
If contacts are integrally formed within an insulator via insert-molding, then manufacturing efficiency is improved, but the complexity of subsequent assembly processes increases
Solution Approach 1:
The patent performs preliminary actions by integrally forming multiple contacts within the insulator through insert-molding before final assembly. The linking sections are removed at an optimal intermediate stage, and holding tabs are pre-positioned to facilitate subsequent gripping and assembly operations, simplifying the overall manufacturing workflow.
Solution Approach 2:
The patent introduces holding tabs as intermediary elements that facilitate the assembly process. These tabs provide gripping points for tools during assembly operations, mediating between the integrally formed contact module and the final assembled connector, thereby reducing assembly complexity despite the initial molding complexity.
3Length of moving object
If linking sections are removed to disconnect neighboring contacts, then fine pitch arrangement is achieved, but the structural strength of the contact module decreases
Solution Approach 1:
The patent merges multiple contacts into a single integrally formed contact module within the insulator. Even after removing linking sections, the contacts remain structurally connected through their integral formation in the molding process, maintaining overall module strength while allowing individual contact separation for fine pitch arrangement.
Solution Approach 2:
The structural strength is established in advance during the insert-molding process where contacts are integrally formed with the insulator. This preliminary structural reinforcement compensates for the subsequent removal of linking sections, allowing fine pitch arrangement without compromising overall module integrity.
Data Source
AI summary
An electrical connector includes an insulative housing, and plural rows of contact modules therein. Each contact module includes plural contacts integrally formed within an insulator/wafter which extends in a longitudinal direction. In each contact module, each contact includes a main body with opposite contacting arms on upper and lower sections wherein the contacts in the same contact carrier are originally linked with the neighboring contacts around lateral sides of the main body for insert-molding consideration, and the corresponding linking sections are removed for disconnecting the neighboring the contacts after insert-molding to form the final complete contact module. Each contacting arm forms a hole with two spaced beams by two sides of the hole. The contact may further include a holding tab exposed in the hole so as to allow a gripping tool to be engaged thereon for assembling the contact module into the channel of the housing.