Flippable Electrical Connector Terminal Alignment
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Solution Overview
Problem
The manufacturing process of USB Type-C connectors is complex and costly due to their large number of terminals, which complicates the assembly and increases production expenses.
Innovation Solution
An electrical connector assembly with a housing and terminals arranged in specific configurations, including a rear base and mating tongue, with upper and lower terminals aligned vertically and pin leg sections aligned front and back, mounted on a printed circuit board with strategically positioned holes for efficient connection and reduced manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If USB Type-C connector with large number of terminals is used, then functionality and versatility are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The connector is divided into two separate components: a receptacle with fewer terminals and a plug with corresponding contacts. This segmentation allows each component to be manufactured with simpler processes while collectively providing the full USB Type-C functionality when mated together.
Solution Approach 2:
The invention introduces a vertical stacking dimension by arranging pin leg sections of upper and lower terminals in different vertical positions. This allows multiple terminals to be integrated in a compact space without increasing the horizontal footprint, maintaining functionality while simplifying manufacturing.
2Adaptability or versatility
If USB Type-C connector with large number of terminals is used, then functionality is improved, but manufacturing cost increases
Solution Approach 1:
By splitting the connector into receptacle and plug components with fewer terminals each, the manufacturing cost of each individual component is reduced. The segmentation allows for simpler tooling and assembly processes while maintaining the overall functionality through the mated connection.
Solution Approach 2:
Instead of manufacturing a single complex connector with many terminals, the invention inverts the approach by creating two simpler connectors that work together. This inversion reduces the manufacturing complexity and cost of each component while achieving the same functional result.
3Productivity
If terminals are arranged with different central pitch in contacting sections, then connection efficiency is improved, but alignment precision requirements increase
Solution Approach 1:
The invention resolves the pitch mismatch by utilizing the vertical dimension. Pin leg sections of upper terminals are positioned at a different vertical level than lower terminals, allowing each row to maintain its own optimal pitch while aligning horizontally with the mating connector.
Solution Approach 2:
The upper and lower terminal rows are nested in the vertical direction with their pin leg sections arranged at different heights. This nesting allows both rows to be integrated into a single connector body without interfering with each other's pitch requirements, enabling efficient assembly while managing alignment precision.
Data Source
AI summary
An electrical connector assembly includes a housing comprising a rear base and a mating tongue extending forward from the base; a row of upper terminals and a row of lower terminals retained on the housing, each terminal including a contacting section exposed to mating tongue and a pin leg section from the base, and the contacting sections of the upper and lower terminals being aligned with each in a vertical direction. The contacting sections of each row terminals are arranged in different central pitch, the pin leg sections of the upper and lower terminals are aligned with each in a front and back direction and the pin leg sections of each row are arranged with a same central pitch.