Offset Substrate Mating Portions for Electrical Terminal Insertion

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Solution Overview

Problem

Existing electrical terminals with compliant contact portions face difficulties in simultaneous insertion into a substrate due to the configuration and close centerline spacing, requiring significant force that can lead to damage or deformation.

Innovation Solution

The electrical terminals feature offset substrate mating portions with shoulder engagement surfaces positioned in a different plane than the transition portions, allowing forces to be transferred through a shoulder engagement surface to an insertion tool, facilitating the insertion process and reducing the risk of damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electrical terminals with compliant contact portions are used for simultaneous insertion into a substrate, then electrical connection reliability is improved, but the insertion force required increases significantly due to close centerline spacing and configuration

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidinsertion force

Core Design Contradiction:

ReliabilityVSForce

Solution Approach 1:

The terminal is divided into distinct functional segments: a compliant contact portion for electrical connection and a separate shoulder portion for force application. This segmentation allows the compliant portion to maintain reliability while the shoulder portion handles the insertion force, preventing damage to the delicate contact areas.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The shoulder acts as an intermediary element between the insertion tool and the compliant contact portion. It transfers insertion forces from the tool to the terminal body without directly loading the fragile compliant contact areas, thereby protecting them from damage while enabling reliable electrical connection.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If compliant contact portions are positioned with close centerline spacing to achieve compact connector design, then device compactness is improved, but the structural strength during insertion deteriorates

Engineering Contradiction:

Improveconnector compactnessVSAvoidstructural strength during insertion

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The shoulder is positioned in a different plane than the longitudinal axis of the transition portion, creating a three-dimensional offset structure. This dimensional change allows the shoulder to provide structural support during insertion while the compliant contact portions maintain their close spacing for compactness, effectively decoupling the strength requirement from the spacing constraint.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The terminal structure employs asymmetric design with the shoulder offset from the central axis in a specific plane. This asymmetry creates a leverage arm that provides mechanical advantage during insertion, enabling the compact closely-spaced terminals to withstand insertion forces without compromising structural integrity.

Inventive Principle:

Principle #4Asymmetry

3Ease of operation

If force is applied directly to compliant contact portions during insertion, then insertion simplicity is improved, but damage or deformation of the compliant portions occurs

Engineering Contradiction:

Improveinsertion simplicityVSAvoiddamage or deformation of compliant portions

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The shoulder serves as a protective intermediary that intercepts insertion forces before they reach the compliant contact portions. This allows simple direct insertion operation while the shoulder shields the vulnerable compliant areas from damaging loads, preventing deformation and damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The shoulder structure provides preemptive protection by being positioned to absorb and distribute insertion forces before they can affect the compliant contact portions. This beforehand cushioning effect prevents damage before it occurs, maintaining both operational simplicity and component integrity.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS11476600B2Electrical terminals with offset substrate mating portions

Publication Date: 2022.10.18 TE CONNECTIVITY SOLUTIONS GMBH

AI summary

An electrical terminal for use with an electrical connector which includes a housing for receiving the electrical terminals therein. The electrical terminals have transition portions and substrate mating portions. The transition portions extend from a rear face of the housing. The substrate mating portions extend from the transition portions. The substrate mating portions have substrate engagement ends configured to be inserted into openings of a substrate. Shoulders are provided on the substrate mating portions. The shoulders are in a different plane than a longitudinal axis of the transition portions. Wherein forces associated with mating the electrical terminals to the substrate are transferred through the shoulders to an insertion tool used to move the terminals into the openings.