Right-Angle Connector Assembly With Two-Piece Terminal Staging
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Solution Overview
Problem
Existing right-angled coaxial electrical connector designs face challenges in assembly complexity and cost inefficiency due to the use of unitary coaxial terminals and cast terminal designs, which are difficult to insert and require costly laser welding.
Innovation Solution
A two-piece electrical terminal design with a separable attachment and connection segment, allowing for easier insertion into an L-shaped terminal cavity and assembly through a movable connection segment that transitions from a pre-staged to a fully staged position, enhancing electrical connectivity and pull-out force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a unitary coaxial terminal with right-angled L-shape is used, then the connector provides structural integrity, but it is difficult to insert into the connector housing and requires complex assembly processes
Solution Approach 1:
The electrical terminal is divided into two separate segments: a connection segment and an attachment segment. The connection segment is inserted into the connector housing first, followed by the attachment segment which is then connected to the connection segment. This segmentation eliminates the difficulty of inserting a rigid right-angled unitary terminal while maintaining structural integrity through the two-segment connection.
2Reliability
If laser welding is used to join connector housing subassemblies, then the connector housing is formed, but the assembly process becomes complex, time consuming, and cost ineffective
Solution Approach 1:
The connector housing is divided into two separate subassemblies that are assembled independently and then joined together. This allows each subassembly to be manufactured separately using simpler, more cost-effective processes, avoiding the need for complex laser welding of a monolithic housing structure.
Solution Approach 2:
The connection segment is pre-assembled with the first connector housing subassembly before the final assembly step. This preliminary action allows for easier integration and reduces the complexity of the final assembly process, eliminating the need for time-consuming laser welding operations.
3Force
If a cast terminal design is used, then the connector provides minimum pull force of 110 newtons, but it is cost ineffective
Solution Approach 1:
The terminal is segmented into connection and attachment portions, allowing the attachment segment to be designed with features that enhance pull force resistance. The connection segment can be optimized for electrical connectivity while the attachment segment handles mechanical strength requirements, enabling cost-effective manufacturing through separate optimization of each segment.
Data Source
AI summary
An electrical connector assembly includes an electrical terminal having an attachment segment connected to an electrical cable and a separate connection segment configured to mate with a corresponding mating terminal and a connector housing defining an L-shaped terminal cavity having a first cavity section in which the connection segment is disposed and a second cavity section arranged substantially perpendicularly to the first section in which the attachment segment is at partially disposed. The connection segment is movable from a pre-staged position in which the connection segment is electrically disconnected from the attachment segment to a fully staged position in which the connection segment is electrically connected to the attachment segment while attached to the connector housing.