Relay Connector Holder Structure for Bent Terminal Alignment
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Solution Overview
Problem
In relay connectors where terminals are press-fit, the deformation of bent portions set in intermediate parts of the terminals is a significant issue, affecting the connector's reliability and performance.
Innovation Solution
The relay connector design includes a connector housing with a partitioning portion containing insertion holes and a holder with grooved holding grooves to accommodate the terminals' bent portions. The terminals have press-fit portions and bent holder portions that are securely held by the holder, preventing deformation during press-fitting and maintaining alignment post-assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminals are press-fit into insertion holes to achieve secure connection, then connection reliability is improved, but bent portions in intermediate parts of terminals deform during the press-fitting process
Solution Approach 1:
The holder is designed to preliminarily hold the bent portions of terminals in their correct positions before the press-fitting process occurs. The holding grooves are pre-formed to match the bent portion geometry, ensuring that when terminals are inserted, the bent portions are already secured in the correct position, preventing deformation during subsequent press-fitting operations.
Solution Approach 2:
The holder acts as an intermediary component between the terminals and the connector housing. It mediates the positioning of terminal bent portions during assembly, using the holding grooves to maintain precise terminal positions while allowing the press-fit portions to be securely connected to the insertion holes without causing terminal deformation.
2Adaptability or versatility
If bent portions are added to terminals to convert array positions, then adaptability to different terminal arrangements is improved, but the terminals become more susceptible to deformation
Solution Approach 1:
The holder serves as a stable intermediary structure that compensates for the reduced stability of bent terminal portions. The holding grooves provide a rigid framework that maintains terminal positions, allowing bent portions to achieve array position conversion without compromising overall structural stability during assembly and operation.
Solution Approach 2:
The holding grooves are designed as precise copies or molds of the terminal bent portions. By creating grooves that exactly match the bent portion geometry, the holder replicates and maintains the intended terminal positions, ensuring that the bent portions remain stable and do not deform even though they have complex geometries for array conversion.
Data Source
AI summary
A relay connector includes a connector housing including a first connector housing portion, a second connector housing portion and a partitioning portion, a plurality of terminals, and a holder for holding the plurality of terminals. The partitioning portion includes a plurality of insertion holes and a holder recess. Each of the plurality of terminals includes an inserting portion, a first terminal portion, a holder held portion, and a second terminal portion. At least one terminal includes a press-fit portion to be press-fit into the insertion hole. At least one terminal includes a bent portion bent with respect to the inserting portion. The holder includes a grooved holder member having a plurality of holding grooves and a lid holder member.