SAS Connector Modular Assembly with Insert-Molded Contacts
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Solution Overview
Problem
The existing SAS connectors face challenges in assembling contacts due to their compact size, which affects reliability and ease of assembly in high-speed serial signal transmission applications.
Innovation Solution
An elongated insulative housing with a bottom mounting portion and a mating portion, featuring a cavity and contact receiving passageways, along with T-shaped locating portions and demising slots, allows for convenient assembly of contact modules with insert-molded contacts and a shielding member for enhanced structural integrity and assembly ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the overall size of the SAS connector is reduced to achieve a compact profile, then the connector size is improved, but the contacts become difficult to assemble into the housing
Solution Approach 1:
The connector is divided into modular components: the housing and separate contact modules. Each contact module is pre-assembled with contacts insert-molded into an insulator, then these modules are inserted into the housing. This segmentation allows contacts to be assembled separately in a controlled manner rather than trying to assemble them directly into the compact housing, resolving the contradiction between compact size and assembly ease.
Solution Approach 2:
The contact modules are nested into the housing cavity. The insulator of each contact module is received within the housing cavity, and the contacts are insert-molded within the insulator. This nested arrangement allows the compact connector structure to accommodate all components without requiring complex assembly operations in the final compact space.
2Manufacturing precision
If contacts are insert-molded in the insulator, then the manufacturing precision and reliability are improved, but the assembly process becomes more complex
Solution Approach 1:
The contact and insulator are merged into a single integrated contact module through insert-molding. This combining of components ensures precise positioning and secure attachment of contacts to the insulator in one manufacturing step, achieving high manufacturing precision while the modular nature of the resulting contact module actually simplifies the overall assembly process.
Data Source
AI summary
An electrical connector includes an insulative housing and two contact modules. The insulative housing has a bottom mounting portion having a cavity opening downwardly and a mating portion, the mating portion has a central mating space and a pair of side walls on both sides of the mating space, and a plurality of contact receiving passageways defined on each side wall. Each contact module has an insulator received in the cavity and a plurality of contacts insert-molded in the insulator, each contact defines a contacting arm and a soldering portion. The insulative housing defines a pair of locating portions extending downwards from two sides of the mounting portion, the distance between the pair of locating portions is smaller than an internal diameter of the cavity, a pair of demising slots are formed on an interior side of each locating portion for the contact modules passing through.