Miniaturized Electrical Connector Layout to Prevent Reverse Mating

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Solution Overview

Problem

Miniaturization of electrical connectors leads to increased susceptibility to misassembly, plastic deformation, and potential short-circuits due to reduced size and rigidity, making it difficult to ensure proper fitting and prevent unwanted contact between terminals.

Innovation Solution

The design incorporates asymmetrical features such as a fastening wall and upward protrusions in the connectors, which prevent reverse mating by ensuring correct alignment and preventing simultaneous contact between power terminals, while maintaining a compact size.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If connector size is reduced to achieve miniaturization, then compactness and reduced dimensions are improved, but susceptibility to misassembly and reverse mating increases

Engineering Contradiction:

Improveconnector sizeVSAvoidassembly accuracy

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent applies asymmetry by configuring the plug connector and receptacle connector with non-symmetrical terminal arrangements and engagement features. The plug connector has signal terminals and power terminals positioned at specific locations, while the receptacle connector has corresponding terminals arranged asymmetrically to prevent reverse mating. This ensures that the connectors can only be assembled in the correct orientation, addressing the misassembly risk introduced by miniaturization.

Inventive Principle:

Principle #4Asymmetry

2Length of moving object

If pitch between electrical terminals is reduced to achieve compactness, then connector dimensions are improved, but probability of short circuit between terminals increases

Engineering Contradiction:

Improvepitch between terminalsVSAvoidshort circuit risk

Core Design Contradiction:

Length of moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent applies segmentation by dividing the connector terminals into distinct functional groups - signal terminals and power terminals - with different structural configurations. The power terminals are designed with enhanced insulation features and positioning structures that segment them from signal terminals, preventing accidental contact and short circuits even when the overall pitch is reduced for compactness.

Inventive Principle:

Principle #1Segmentation

3Volume of moving object

If connector components are downsized to achieve miniaturization, then compactness is improved, but durability and resistance to deformation worsen

Engineering Contradiction:

Improveconnector components sizeVSAvoidresistance to breakage

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The patent applies composite materials by combining metal terminals with plastic housing and insulation materials in a integrated connector structure. The terminals are made of metal for strength and conductivity, while the housing provides structural support and protection. This composite construction maintains durability and resistance to deformation even when the overall connector size is reduced, as each material contributes its optimal properties to the miniaturized design.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12586956B2Miniaturized electrical connector with features to prevent short circuit of power terminals

Publication Date: 2026.03.24 HIROSE KOREA CO LTD

AI summary

Disclosed herein is a pair of electrical connectors including a plug connector and a receptacle connector. The plug connector includes a plug housing, a plug signal terminal, a plug power terminal, and a fastening wall. The receptacle connector includes a receptacle housing, a receptacle signal terminal, a receptacle power terminal, and a fastening groove. With the plug connector completely fitted into the receptacle connector, the fastening wall is placed on the fastening groove.