Monolithic Connector Terminals Eliminate Bridge Insert
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Solution Overview
Problem
The existing connector assemblies for electrically connecting circuit boards are complex and costly to manufacture due to the intricacies of the insulative housings and the need for a separate intermediate bridge insert.
Innovation Solution
A connector assembly featuring monolithically formed conductive terminals on each connector, which mate to electrically connect two circuit boards without the need for a separate bridge insert, utilizing elastic clamps and a release mechanism for secure and easy connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connector assemblies with separate insulative housings and intermediate bridge inserts are used, then reliable electrical connection between circuit boards is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the intermediate bridge insert function directly into the connector housing structure. The housing now serves dual purposes: providing mechanical support and insulation while simultaneously establishing electrical connections through integrated contact elements. This eliminates the need for separate bridge inserts and reduces the number of components.
Solution Approach 2:
The connector housing is designed to perform multiple functions simultaneously: mechanical support, electrical insulation, and electrical connection establishment. The contact elements are integrated into the housing structure, allowing the same component to provide both structural and electrical functions, thereby simplifying the overall assembly.
2Reliability
If traditional connector assemblies with separate intermediate bridge inserts are used, then electrical connection between circuit boards is achieved, but manufacturing cost increases
Solution Approach 1:
By merging the bridge insert functionality into the housing structure, the patent reduces the total number of parts that need to be manufactured, stored, and assembled. This consolidation directly reduces manufacturing costs through fewer production lines, lower inventory requirements, and simplified assembly processes.
Solution Approach 2:
The connector is designed as a modular assembly where the housing with integrated contacts can be manufactured as a single unit or in standardized batches. This segmentation allows for optimized production runs and reduced tooling costs compared to manufacturing multiple separate components.
3Ease of manufacture
If monolithically formed conductive terminals are used, then manufacturing process is simplified and costs are reduced, but connection complexity must be managed
Solution Approach 1:
The monolithic conductive terminals are integrated directly into the housing structure, combining the terminal and housing into a single manufactured component. This eliminates the need for separate terminal assembly steps and reduces overall connector complexity while maintaining manufacturing simplicity.
Data Source
AI summary
A connector assembly comprises a first connector and a second connector. The first connector consists of a first monolithically formed conductive terminal adapted to be soldered onto a first circuit board. The second connector consists of a second monolithically formed conductive terminal adapted to be soldered onto a second circuit board. The first connector mates with the second connector to electrically connect the first circuit board to the second circuit board.