RJ-Type Connector Secured Contacts via Spacer Blocking
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Solution Overview
Problem
Existing electrical connectors on PCBs face instability due to distortion of insulating housing and spacer during soldering, leading to weak connections and potential separation of terminals from the housing under force, resulting in an unstable mating connection.
Innovation Solution
An electrical connector design featuring an insulating housing with passageways and a first spacer member with blocking portions that resist tabs of the contacts, ensuring a stable connection by preventing backward movement of the contacts during mating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrical connector uses a traditional spacer and terminal structure, then the assembly is simple to manufacture, but the connection becomes unstable due to distortion during soldering and weak interference between terminal and spacer
Solution Approach 1:
The connector is divided into distinct functional modules: insulating housing with integrated passageways, separate contacts with holding beams, and a first spacer member with blocking portions. This segmentation allows each component to perform its specific function optimally while maintaining overall connection stability despite soldering distortions
Solution Approach 2:
The blocking portions of the first spacer member are pre-positioned to engage with the tabs of the contacts before any distortion occurs during soldering. This preliminary mechanical constraint prevents the contacts from moving backward even when thermal distortion weakens other connection points, ensuring reliability from the outset
2Reliability
If the terminals are engaged with the mating connector with large force, then the electrical connection is secure, but the terminals are pushed backward from the passageways and separated from the insulating housing
Solution Approach 1:
The blocking portions of the first spacer member apply a preliminary counter-force to the tabs of the contacts in the backward direction. This pre-applied anti-action counterbalances the forward pushing force during mating, preventing the terminals from being pushed backward out of the passageways while still allowing secure electrical connection
Solution Approach 2:
The solution introduces a new dimensional constraint by adding the first spacer member that engages with the tabs of the contacts. This creates a multi-dimensional constraint system where the blocking portions provide restraint in the backward direction, complementing the existing lateral and forward constraints, thereby stabilizing terminal position under mating force
Data Source
AI summary
An electrical connector comprises an insulating housing defining a receiving room with a front mating opening and a plurality passageways extending rearwards, a plurality of contacts retained in the passageways, and a first spacer member retained in the insulating housing and sustaining said contacts upwardly. Each contact comprises a holding beam with tabs formed thereon and a holding leg downwardly extending from a rear end of the holding beam. Said first spacer member has a plurality of blocking portions which are formed on a rear side of said tabs to resist the tabs frontward so that the contacts can not move rearwards but be retained in the insulating housing stably even during the mating process with a mating connector.