Plug Connector Assembly With Interference-Assembled Contacting Modules
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Solution Overview
Problem
Existing plug connector assemblies have complex and costly assembly processes due to the need for separate alignment and installation of contacting modules within an insulative housing.
Innovation Solution
A plug connector assembly design featuring a mating member with an insulative housing that includes engagement structures allowing interference assembly of first and second contacting modules, which are then integrated and inserted into the housing, simplifying the assembly process and reducing costs by using a common engagement structure for both insulative members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If contacting modules are assembled separately into the insulative housing, then each module can be individually installed, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple contacting modules (first contacting module and second contacting module) into a single integrated assembly unit. The first and second insulative members are pre-assembled together with their respective contacting modules, forming a unified structure that is then installed as one piece into the housing, eliminating the need for separate alignment and installation of each module.
Solution Approach 2:
The first and second insulative members are pre-assembled together before final installation into the housing. This preliminary assembly action allows the contacting modules to be prepared and aligned in advance, reducing the complexity and time of the final assembly process.
2Ease of manufacture
If multiple contacting modules are assembled separately, then individual installation is possible, but assembly cost increases
Solution Approach 1:
The patent merges the first and second contacting modules into a single assembly unit by integrating their insulative members. This reduction in the number of separate assembly operations directly lowers production costs while simplifying the overall assembly process.
Solution Approach 2:
The housing is designed with a universal mounting structure that can accommodate the integrated contacting module assembly. The mounting slot and engagement structures provide a multi-functional solution that handles both support and alignment functions in a single design, reducing the need for additional components.
3Loss of time
If contacting modules are pre-assembled into a unit, then assembly is simplified, but the structure becomes more complex
Solution Approach 1:
The patent segments the insulative members by providing distinct first and second insulative members that can be separately manufactured and then assembled together. This segmentation allows for modular production while creating a simplified integrated assembly that improves assembly efficiency.
Solution Approach 2:
The engagement structures act as intermediaries between the first and second insulative members, providing a standardized interface for their connection. This intermediary mechanism simplifies the assembly process by providing clear alignment and connection points without requiring complex integration.
Data Source
AI summary
A plug connector assembly includes a cable and a mating member electrically connected to the cable, the mating member having an insulative housing and a contacting module retained in the insulative housing, the contacting module having a first contacting module unit and a second contacting module unit, the first contacting module unit having plural first contacts arranged along a lateral direction and a first insulative member retaining the first contacts, the second contacting module unit having plural second contacts arranged along the lateral direction and a second insulative member retaining the second contacts, wherein each of the first and second insulative members includes a same engagement structure, through which the first insulative member and the second insulative member are assembled into a whole by interference arrangement and then inserted into the insulative housing together.