Modular Electrical Connector Assembly Kit Reducing Tooling Complexity

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Solution Overview

Problem

Conventional pin header connectors require unique tooling and increased manufacturing costs and assembly time due to their complexity, especially as pin count and variations grow, limiting flexibility and efficiency.

Innovation Solution

A modular electrical connector assembly kit using a common insulative header component with receptacle spaces and interchangeable contact sub-assemblies of varying configurations, allowing for different contact element arrangements and configurations to be assembled into a single connector configuration, reducing tooling and assembly costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional pin header connectors are manufactured with unique tooling for each variation, then manufacturing precision and reliability are improved, but manufacturing cost and device complexity increase significantly

Engineering Contradiction:

Improveconnector reliabilityVSAvoidtooling complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies universality by designing a single standardized tooling system that can manufacture multiple connector variations. The housing and contact assembly tooling are designed to accommodate different pin counts, arrangements, and configurations through programmable assembly sequences rather than requiring unique tooling for each variant. This allows one set of tools to perform multiple manufacturing functions across different connector types.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The connector is segmented into modular components: a standardized housing, interchangeable contact assemblies, and configurable contact elements. This segmentation allows the manufacturing process to be divided into separate stages where common components are manufactured once and then configured into different final products through assembly variations, reducing the need for complete retooling for each connector type.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If pin count and contact element variations increase, then connector versatility and adaptability are improved, but assembly time and manufacturing cost increase

Engineering Contradiction:

Improveconnector versatilityVSAvoidassembly speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

Contact assemblies are pre-assembled and pre-configured as modular units before being integrated into the final connector housing. This preliminary assembly allows contact elements to be organized and prepared in advance according to different pin configurations, reducing the complexity and time required during final assembly. The pre-prepared contact assemblies can be quickly installed into the housing without requiring complex on-site configuration.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The manufacturing system incorporates dynamic, programmable assembly sequences that can be reconfigured for different connector variations. Rather than fixed assembly lines for each connector type, the system uses controllable assembly mechanisms that can adapt their motion paths, sequencing, and configuration parameters based on the desired connector variant, enabling rapid changeover between different pin counts and arrangements.

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If unique tooling is used for each connector variation, then manufacturing precision is maintained, but manufacturing cost increases

Engineering Contradiction:

Improveconnector manufacturing precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

A universal tooling system with standardized fixtures, jigs, and assembly equipment is designed to accommodate multiple connector variations. The tooling incorporates adjustable and reconfigurable elements that can be programmed or adjusted to produce different pin counts, contact arrangements, and configurations while maintaining consistent manufacturing precision through controlled parameters and quality assurance processes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The manufacturing process uses parameter-based control where key dimensions, positions, and configurations are defined as adjustable parameters rather than fixed tooling geometries. By changing these parameters (such as contact spacing, pin count, arrangement patterns) through software control or reconfigurable fixtures, the same tooling can produce different connector variants with maintained precision without requiring physical retooling for each variation.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP3236538B1Modular electrical connector assembly kit and associated method of making

Publication Date: 2022.03.16 KYOCERA AVX COMPONENTS CORP

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AI summary

A method for producing an electrical connector fitting a combination of common-sized contact sub-assemblies into receptacle spaces in a common insulative header component to define a desired pattern, wherein the common-sized contact sub-assemblies have varying contact element configurations such that a first of the common-sized contact sub-assemblies has a different contact element configuration than a second of the common-sized contact sub-assemblies; and attaching the common-sized contact sub-assemblies to the header component.