Movable Connector Terminal Segmentation for Stress Reduction
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Solution Overview
Problem
Movable connectors with press-fitted terminals often experience residual stress, especially in high-temperature environments, and insert molding can lead to complex mold designs, limiting the design freedom of movable housings.
Innovation Solution
A movable connector design that uses insert molding for retaining terminals in the stationary housing and press-fitting for the movable housing, with integrated restriction fittings to secure the movable housing's position and allow for assembly through a through-pass section, reducing residual stress and enhancing design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If press-fitting is used to retain terminals in housings, then assembly is simple and fast, but residual stress remains in the housing causing deformation in high temperature environments
Solution Approach 1:
The terminal is divided into two distinct retained portions: a stationary-side retained portion (32) that is insert-molded into the stationary housing (20), and a movable-side retained portion (34) that is press-fitted into the movable housing (50). This segmentation allows different retention methods to be applied to different parts of the same terminal, resolving the contradiction between assembly simplicity and residual stress reduction.
2Reliability
If insert molding is used to retain terminals in housings, then residual stress is suppressed, but mold complexity increases and design freedom is limited
Solution Approach 1:
Insert molding is applied locally only to the stationary-side retained portion (32) of the terminal where residual stress suppression is critical, while the movable-side retained portion (34) uses simpler press-fitting. This localized application of insert molding reduces mold complexity compared to full insert molding, while still achieving the primary goal of suppressing residual stress in the stationary housing.
3Reliability
If insert molding is performed on both housings, then residual stress is suppressed in both, but the movable housing design freedom is restricted
Solution Approach 1:
The terminal retention system is segmented into two portions with different retention methods: the stationary-side retained portion (32) uses insert molding to suppress residual stress, while the movable-side retained portion (34) uses press-fitting to maintain design freedom. This segmentation allows the movable housing (50) to be designed with greater flexibility for various connector types and applications.
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
This approach effectively suppresses residual stress in the stationary housing and secures design freedom for the movable housing, enabling reliable assembly and operation while maintaining electrical characteristics.
Implementation Method 1
retention of the stationary-side retained portion with respect to the stationary housing is achieved by performing insert molding
Implementation Method 2
retention of the movable-side retained portion with respect to the movable housing is achieved by performing press-fitting
Implementation Method 3
an elastically deformable movable portion positioned between the stationary-side retained portion and the movable-side retained portion
Data Source
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AI summary
A movable connector (100) including a stationary housing (20) to be fixed to a substrate, a movable housing (50) capable of moving relative to the stationary housing (20), and a terminal (30) including a stationary-side retained portion (32) retained at the stationary housing (20), a movable-side retained portion (34) retained at the movable housing (50) and an elastically deformable movable portion (33) positioned between the stationary-side retained portion (32) and the movable-side retained portion (34). Retention of the stationary-side retained portion (32) with respect to the stationary housing (20) is achieved by performing insert molding. Retention of the movable-side retained portion (34) with respect to the movable housing (50) is achieved by performing press-fitting.