Shielded Connector Assembly for Accurate Terminal Positioning
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Solution Overview
Problem
Current connectors face challenges with low assembly yield and inefficient manufacturing processes due to the complexity of positioning multiple terminals, which can lead to short circuits and reduced transmission efficiency.
Innovation Solution
The connector design includes a casing with a base, rear plug, and shielding components, where first and second terminals are insert molded and bent to be fixed by the lower portion and rear plug in different directions, simplifying assembly steps and improving yield and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple terminals are inserted into through holes for positioning, then terminal positioning accuracy is improved, but assembly yield decreases and manufacturing complexity increases
Solution Approach 1:
The patent combines multiple terminal positioning operations into a single integrated base structure with pre-formed positioning features. The base includes integrated positioning protrusions and guiding structures that simultaneously position multiple terminals during one molding operation, eliminating the need for separate through-hole insertion steps for each terminal.
Solution Approach 2:
The base structure is pre-formed with integrated positioning features, guiding walls, and support structures before terminal assembly. The molding process creates built-in positioning mechanisms that automatically guide terminal placement, performing the positioning function in advance rather than requiring separate positioning steps during assembly.
2Manufacturing precision
If multiple terminals are inserted into through holes for positioning, then terminal positioning accuracy is improved, but manufacturing process complexity increases
Solution Approach 1:
The patent merges the base structure and positioning mechanisms into a single integrated component. The base includes integrated positioning protrusions, guiding walls, and support structures that work together as one unit, eliminating the need for multiple separate positioning components and reducing manufacturing process complexity.
Solution Approach 2:
The base structure serves multiple functions simultaneously: it provides mechanical support for terminals, integrates positioning features for accurate terminal placement, includes guiding walls for alignment, and incorporates support structures for structural integrity. This multi-functional design reduces the number of separate components needed.
3Adaptability or versatility
If connectors are made smaller with more terminals, then transmission specifications are improved, but assembly difficulty increases
Solution Approach 1:
The patent segments the connector into modular components: a base with integrated positioning features, terminal assemblies, and shielding structures. This segmentation allows each component to be manufactured and positioned independently with built-in guidance, making assembly of high-density terminals easier despite the compact size.
Solution Approach 2:
The patent utilizes three-dimensional space efficiently by incorporating vertical positioning features, layered shielding structures, and multi-level terminal arrangements. The base includes vertical guiding walls and stepped positioning surfaces that enable precise terminal placement in a compact footprint, accommodating more terminals without increasing overall connector size.
Data Source
AI summary
A connector including a casing, a base, a rear plug, a plurality of first terminals, a plurality of second terminals, a middle shielding, an upper shielding and a lower shielding. The base is disposed in the casing and includes an upper portion, a middle portion and a lower portion. The rear plug is disposed at a side of the lower portion. The first terminals are insert molded on the upper portion. Each of the second terminals includes a first portion and a second portion that are connected in a bent manner. The first portions are insert molded on the lower portion, and the second portions are insert molded on the rear plug. The middle shielding passes through the middle portion and is disposed between the first terminals and the second terminals. The upper shielding and the lower shielding are fixed to the base.