Plug Assembly Molding for Terminal Positioning Accuracy
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Solution Overview
Problem
Existing electrical connectors with a large number of conductive terminals face challenges in accurately positioning these terminals during manufacturing, affecting the reliability of interconnections in communication systems like network systems and data centers.
Innovation Solution
A plug assembly with conductive terminals secured to an insulating main body through molding, featuring supporting through holes and contact surfaces exposed from the sidewall, allowing for precise positioning and stable electrical contact, and utilizing injection molding to fix the terminals in place with support pillars, ensuring accurate alignment and reduced signal crosstalk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large number of conductive terminals are mounted on the insulating main body, then the data transmission capacity is improved, but the positioning accuracy of the conductive terminals deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-forming positioning protrusions on the insulating main body before mounting the conductive terminals. These positioning protrusions are created during the injection molding process of the insulating main body, establishing precise positioning structures in advance that guide and constrain the conductive terminals to accurate positions during subsequent assembly, thereby maintaining high positioning accuracy even when a large number of terminals are mounted
Solution Approach 2:
The patent replaces traditional mechanical positioning methods (such as manual positioning or complex mechanical fixtures) with an integrated molding approach. The positioning protrusions are formed directly within the insulating main body through injection molding, eliminating the need for separate positioning mechanisms and enabling precise positioning of numerous conductive terminals through the molded structural features alone
Data Source
AI summary
A plug assembly includes an insulating main body and a plurality of conductive terminals secured to the insulating main body by molding. The insulating main body has a mating portion adapted to mate with a receptacle assembly and a plurality of supporting through holes. Each of the conductive terminals has a contact portion with a contact surface. The contact surface is exposed from a sidewall of the mating portion. Each of the supporting through holes extends to a rear surface of one of the conductive terminals opposite to the contact surface from a rear side of the insulating main body.