Stacked Terminal Module Connector With Shared Mold Structure
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Solution Overview
Problem
Existing electrical connector assemblies for high-speed signals in communication infrastructure require different stamping dies and forming dies for upper and lower terminal modules, leading to high manufacturing costs.
Innovation Solution
Designing an electrical connector assembly where the first and second terminal modules share the same structure, allowing them to be manufactured using the same mold, with each module having a row of terminals arranged in a transverse direction and including sideband and high-speed terminal areas, enabling cost reduction while maintaining structural simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If different stamping dies and forming dies are used for upper and lower terminal modules, then the structural requirements of each module can be met, but the manufacturing cost increases
Solution Approach 1:
The patent applies universality by designing the upper and lower terminal modules with identical structures, allowing a single stamping die and forming die to produce both modules. The terminal modules share the same terminal row configuration, insulator design, and housing integration method, enabling one mold to serve multiple functions and eliminate the need for separate tooling for each module type.
Solution Approach 2:
The patent implements homogeneity by making the upper and lower terminal modules structurally identical. Both modules use the same terminal arrangements (including high-speed and sideband terminals), the same insulator geometry, and the same integration approach with the housing. This uniformity allows standardized manufacturing processes and reduces the variety of components that require different manufacturing tools.
2Ease of manufacture
If the same mold is used for both terminal modules, then manufacturing cost is reduced, but the structural design must be simplified
Solution Approach 1:
The terminal module design achieves universality by creating a standardized configuration that can be used for both upper and lower positions. The module incorporates all necessary terminal types (high-speed and sideband terminals) in a symmetric arrangement that functions equally well in either orientation, allowing the same molded structure to fulfill multiple positional requirements without modification.
Solution Approach 2:
The patent applies segmentation by dividing the connector into identical, repeatable terminal module units. Each module is an independent, self-contained assembly with standardized interfaces and internal structure. This modular approach allows the same module design to be replicated multiple times (for upper and lower positions) while maintaining functional independence and ease of assembly.
3Area of stationary object
If terminal modules are stacked vertically, then space is saved, but assembly precision requirements increase
Solution Approach 1:
The connector is segmented into discrete, stackable terminal modules that can be vertically arranged. Each module serves as an independent unit with standardized dimensions and interface features, enabling precise stacking through repeated placement of identical components. The segmentation allows for modular assembly where alignment features on each module ensure accurate positioning relative to adjacent modules.
Solution Approach 2:
The terminal modules are pre-formed with integrated alignment features (such as positioning protrusions or guide structures) that ensure correct stacking orientation and position. This preliminary incorporation of alignment mechanisms into the module design itself eliminates the need for complex external alignment procedures during assembly, thereby reducing the actual assembly precision requirements while maintaining compact vertical stacking.
Data Source
AI summary
An electrical connector assembly includes: an insulative housing; a terminal module including a first terminal module and a second terminal module stacked with each other in a vertical direction; and a cable electrically connected to the terminal module; wherein the first terminal module includes a first row of terminals and a first insulating member holding the first row of terminals, the second terminal module includes a second row of terminals and a second insulating member holding the second row of terminals, each of the first row of terminals and the second row of terminals include a sideband terminal area and high-speed terminal areas located on the two sides of the sideband terminal area, the cable is mechanically and electrically connected to the high-speed terminal area, and the first row of terminals and the second row of terminals have same structure.