Joint Connector with Alternating Ferrite Cores for Miniaturization
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Solution Overview
Problem
Existing joint connectors are complicated and costly due to strict dimension control requirements and are larger than general-purpose connectors due to wider intervals between needle shape terminal portions, which are not compatible with standard connectors.
Innovation Solution
A joint connector design featuring a terminal with a busbar and needle shape terminal portions, where a first ferrite core is placed at the base end and a second ferrite core at the intermediate portion, arranged alternately to reduce the interval between terminal portions to match general-purpose connectors, allowing for miniaturization and compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a ferrite component is provided with through holes for inserting needle shape terminals, then noise radiation is reduced, but the structure becomes complicated and dimension control becomes strict
Solution Approach 1:
The ferrite component is divided into multiple segments (first ferrite component and second ferrite component) that are arranged alternately along the needle shape terminal portions. This segmentation allows each ferrite component to have a simpler structure without through holes, while collectively providing the noise radiation reduction function across multiple locations.
Solution Approach 2:
The through holes are extracted from the ferrite component design. Instead of having through holes in the ferrite component, the needle shape terminals are inserted through the connector housing, and the ferrite components are positioned at the base ends and intermediate portions of the terminals without requiring through holes in the ferrite material itself.
2Ease of manufacture
If the interval between needle shape terminal portions is wider to accommodate ferrite components, then ferrite components can be properly installed, but the joint connector becomes larger than general-purpose connectors
Solution Approach 1:
The ferrite components are arranged in a longitudinal sequence along the needle shape terminal portions rather than being placed side-by-side. The first ferrite component is positioned at the base end and the second ferrite component at the intermediate portion, utilizing the length dimension of the terminal to accommodate both ferrite components without increasing the lateral interval between terminal portions.
Solution Approach 2:
The two ferrite components are nested along the length of the needle shape terminal portions in an alternating arrangement. This nested positioning allows both ferrite components to be accommodated within the existing dimensional constraints of the connector, maintaining compatibility with general-purpose connector intervals.
3Manufacturing precision
If strict dimension control is required for through holes in ferrite component, then proper terminal insertion is achieved, but manufacturing cost increases
Solution Approach 1:
The through holes are extracted from the ferrite component design and relocated to the connector housing structure. The ferrite components themselves no longer require precision-machined through holes, which eliminates the need for strict dimension control on the ferrite components and reduces manufacturing complexity and cost.
Solution Approach 2:
The functional requirement for through holes is segmented and redistributed. Instead of requiring through holes in the ferrite component, the design separates the insertion function (handled by connector housing) from the noise suppression function (handled by ferrite components), allowing each element to be manufactured with appropriate but less stringent tolerances.
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 alternately arranged ferrite cores allow for a miniaturized joint connector with the same terminal spacing as general-purpose connectors, enabling electrical connectivity while maintaining a simple structure and reducing costs.
Implementation Method 1
The joint connector includes a ferrite component to remove noise overlapped on the data for reducing bad effect on transmitting data, which controls various electric unit mounted in the car through CAN communication, by noise radiation
Data Source
AI summary
For providing a joint connector which is miniaturized and general-purpose by designing an interval between needle shape terminal portions same as an interval between terminals of the general-purpose connector, the joint connector 1 includes a terminal 3 with a ferrite core 10, and a connector housing 2 receiving the terminal 3. The terminal 3 includes a busbar 28 and a plurality of needle shape terminal portions 29 extending from the busbar 28 at intervals along a direction of lengthwise of the busbar 28. The ferrite core 10 includes a first ferrite core 10a arranged at a base end 29a of the needle shape terminal portion 29 and a second ferrite core 10b arranged at an intermediate portion 29b of the needle shape terminal portion 29. The first ferrite core 10a and the second ferrite core 10b are arranged alternately at each of the plurality of needle shape terminal portions 29.