Multipolar Connector Assembly via Bending Portions
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Solution Overview
Problem
Existing multipolar connectors require high positional accuracy for assembly, making the manufacturing process complex and costly.
Innovation Solution
A multipolar connector design where an insulating member is fixed to an external terminal by bending portions, eliminating the need for high positional accuracy during assembly, with the insulating member being pressed by the external terminal's bending portions onto its outer frame portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple fixing positions (latch holes and recess) are used to attach the metal shell to the insulating block, then the strength of the multipolar connector is improved, but high positional accuracy is required for the fixing portions, making the manufacturing process complex and increasing manufacturing costs
Solution Approach 1:
The patent changes the fixing mechanism from multiple discrete fixing points (latch holes and recess) to a continuous fixing interface. The insulating block is designed with an inclined surface that contacts a corresponding inclined surface on the housing, creating a large-area contact zone. This continuous interface naturally accommodates positional variations without requiring high precision, while still providing strong fixation through the distributed contact area.
Solution Approach 2:
The patent divides the fixing function into two independent parts: the inclined surface for positioning and accommodation of dimensional variations, and the rib-protrusion mechanism for providing fixation force. This segmentation allows each part to perform its specific function optimally without interfering with the other, reducing the overall complexity and precision requirements.
2Reliability
If multiple fixing positions are used to securely engage components, then the reliability of the connection is improved, but the device complexity increases due to multiple fixing features
Solution Approach 1:
The patent merges the positioning function and the fixation function into a unified mechanism. The inclined surface provides both positioning (by guiding the relative position of components) and fixation (through friction and normal force). The rib fitting into the protrusion provides additional fixation while the inclined surfaces accommodate dimensional variations. This merging reduces the number of separate features needed compared to traditional multiple discrete fixing points.
3Strength
If high positional accuracy is required for component assembly, then the connection strength is improved, but the ease of manufacture deteriorates due to complex manufacturing processes
Solution Approach 1:
The patent changes the geometric parameters of the fixing interface by introducing inclined surfaces with specific angles. These inclined surfaces transform point-contact fixation into surface-contact fixation, increasing the effective contact area and distributing mechanical stresses. This parameter change allows the connection to maintain strength while being tolerant of positional variations, greatly simplifying the manufacturing and assembly processes.
Data Source
AI summary
A multipolar connector capable of easily assembling components thereof without requiring high positional accuracy for portions of the components that are to be fixed to each other. A multipolar connector is a multipolar connector for use in electrically connecting circuit boards to each other. The multipolar connector includes an external terminal that is fixed to a circuit board, an insulating member that is fixed to the external terminal, and internal terminals that are respectively fitted to grooves, which are formed in the insulating member, so as to be partially exposed through the insulating member. The insulating member is placed such that the bottom surface thereof is in contact with an outer frame portion of the external terminal and fixed to the external terminal as a result of the top surface thereof being pressed by bending portions of the external terminal toward the outer frame portion.