Power Connector Assembly Direct Wire Soldering
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Solution Overview
Problem
Existing power connector assemblies face challenges in conveniently soldering contacts to cable wires, particularly due to complex manufacturing processes and higher costs associated with the use of printed circuit boards.
Innovation Solution
A power connector assembly design featuring a cable with multiple wires, an insulative housing, and contacts with specifically arranged soldering portions that allow for direct soldering of all soldering areas at once, eliminating the need for a printed circuit board, thereby simplifying the manufacturing process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a printed circuit board is used to connect contacts to cable wires, then connection reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts and eliminates the printed circuit board from the connector assembly, allowing contacts to be directly soldered to cable wires. This removes the intermediate PCB layer while maintaining reliable electrical connections, thereby reducing device complexity and manufacturing cost without sacrificing connection reliability.
Solution Approach 2:
The patent merges the contact mounting function and wire connection function into a single integrated structure. The contacts are directly soldered to the cable wires, combining what were previously separate functions (contact attachment to PCB and PCB-to-wire connection) into one direct solder joint, simplifying the overall assembly.
2Manufacturing precision
If a printed circuit board is used to connect contacts to cable wires, then manufacturing precision is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent removes the printed circuit board from the manufacturing process, eliminating the need for PCB fabrication, drilling, plating, and assembly operations. Contacts are directly soldered to wires, significantly simplifying the manufacturing process while maintaining precise electrical connections through proper soldering techniques.
3Ease of operation
If soldering areas are arranged at different positions, then individual soldering flexibility is improved, but soldering time and productivity decrease
Solution Approach 1:
The patent merges all soldering areas into a single common horizontal plane, allowing multiple contacts to be soldered to their respective wires simultaneously in one operation. This eliminates the need for sequential soldering of individually positioned contacts, dramatically improving productivity while maintaining the flexibility needed for proper solder joint formation.
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 design simplifies the manufacturing process and reduces costs by enabling direct simultaneous soldering of all soldering areas to the wires, ensuring efficient assembly and effective connection without the need for a printed circuit board.
Implementation Method 1
each of the first soldering portions and the second soldering portion comprises a soldering area soldered to a respective one of the wires
Data Source
AI summary
A power connector assembly (100) includes a cable (7) including a number of wires (70), an insulative housing (1), and a number of electrical contacts (2). The electrical contacts include at least one detection contact (22) and plural contacts (21). Each of the plural contacts includes a pair of mating portions (211), a pair of middle portions (212) extending rearwardly from the mating portions respectively, a connecting portion (213) connected with the middle portions, and a first soldering portion (214) connected with the connecting portion. The at least one detection contact includes a second soldering portion (223). Each of the first soldering portions and the second soldering portion includes a soldering area soldered to respective one of the wires, and all of the soldering areas are disposed at a common horizontal plane, arranged in a straight line, and soldered to corresponding wires at same time.