Split Connector Housing for Low-Force FPC Terminal Assembly
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Solution Overview
Problem
Existing electrical connectors for flexible printed circuit boards face challenges such as high insertion force requirements due to friction, potential damage during insertion, poor adhesive tolerance, and inaccurate alignment, which complicate the assembly process and increase quality risks.
Innovation Solution
The electrical connector housing features a split design with a terminal receiving housing part and a cover part that can be assembled independently, incorporating snap-fit engagement portions and locking mechanisms to facilitate easy assembly with reduced external force, ensuring accurate alignment and secure locking of connection terminals and circuit boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the assembly of flexible printed circuit board and connection terminals is inserted into the housing as a whole, then physical and electrical connections are achieved, but the insertion force becomes excessively large due to friction between elastic sheets and housing pocket
Solution Approach 1:
The invention divides the housing into two separate parts: a first housing part that receives the connection terminals and a second housing part that receives the flexible printed circuit board. This segmentation allows the connection terminals to be pre-assembled with the circuit board outside the housing, then inserted together as a complete assembly, significantly reducing the insertion force required while maintaining reliable electrical connections.
2Reliability
If the assembly is inserted as a whole, then connection is achieved, but the copper foils of crimping portions are easily damaged during insertion
Solution Approach 1:
The connection terminals are pre-installed on the flexible printed circuit board before insertion into the housing. This preliminary assembly allows the crimping connections to be formed and protected beforehand, preventing damage to the copper foils during the insertion process into the housing.
3Ease of manufacture
If the housing uses a unified structure, then manufacturing is simple, but the tolerance for adhesive dispensing thickness is poor and insertion becomes difficult
Solution Approach 1:
The housing is divided into two independent parts that can be manufactured separately with different structural optimizations. The first housing part can accommodate the connection terminals with appropriate adhesive tolerance, while the second housing part is designed to receive the flexible printed circuit board assembly, allowing each part to be optimized for its specific function and improving overall insertion ease.
4Ease of manufacture
If the housing structure is simplified, then manufacturing is easier, but accurate alignment between connection terminals and through holes cannot be ensured
Solution Approach 1:
By dividing the housing into two separate parts, each part can incorporate specific alignment features optimized for its function. The first housing part can include guide structures for connection terminal alignment, while the second housing part provides alignment features for the flexible printed circuit board, ensuring precise positioning without complicating the overall manufacturing process.
Data Source
AI summary
An electrical connector housing includes a terminal receiving housing part and a cover part independent of the terminal receiving housing part. The terminal receiving housing part defines a receiving slot receiving a plurality of connection terminals and a circuit board. The terminal receiving housing part and the cover part are capable of being assembled together.