Staggered Connector Terminal Layout With Planar Mold Surfaces
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Solution Overview
Problem
Existing connector assemblies have high manufacturing costs due to complex metal molds required for insert-molding of plug connectors with staggered terminals.
Innovation Solution
The connector assembly features plug and receptacle connectors with staggered terminals, where the main contact portion of each plug terminal is flush with the support contact portion of the adjacent terminal, allowing for a simple planar metal mold surface during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plug terminals are arranged in a staggered pattern, then contact reliability is improved, but metal mold complexity increases
Solution Approach 1:
The plug terminal is divided into functionally independent portions: a main contact portion for primary electrical connection and a support contact portion for secondary connection and structural support. This segmentation allows each portion to be formed by simple planar metal mold surfaces, eliminating the need for complex molded features while maintaining the staggered arrangement benefits.
Solution Approach 2:
Instead of using the metal mold to create complex three-dimensional terminal shapes directly, the invention inverts the approach by using simple planar mold surfaces to form terminals with distinct functional portions. The complexity is resolved by recognizing that functional differentiation can be achieved through simple geometric segmentation rather than complex molding.
2Manufacturing precision
If complex metal molds are used for insert-molding, then terminal formation precision is improved, but manufacturing cost increases
Solution Approach 1:
The terminal is segmented into main contact portion and support contact portion, each formed by dedicated planar metal mold surfaces. This segmentation maintains precise terminal formation through simple, cost-effective molding processes without requiring complex multi-cavity or progressive molds.
Solution Approach 2:
The invention changes the geometric parameters of the metal mold from complex three-dimensional surfaces to simple planar surfaces. This parameter change reduces manufacturing cost while maintaining terminal formation precision through proper positioning and alignment of the planar mold surfaces during the insert-molding process.
3Device complexity
If main contact portion and support contact portion are integrated, then structural simplicity is improved, but contact reliability decreases
Solution Approach 1:
The terminal structure is segmented into distinct main contact portion and support contact portion with separate functions. The main contact portion provides primary electrical connection while the support contact portion provides secondary connection and mechanical support. This functional segmentation enhances contact reliability without significantly increasing overall structural complexity.
Solution Approach 2:
While functionally segmented, the main contact portion and support contact portion are merged into a single integrated terminal component formed in one insert-molding process. This merging maintains structural simplicity and manufacturing efficiency while achieving reliable contact through functional differentiation within the unified structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration reduces manufacturing costs by simplifying the metal mold design while maintaining a tactile click sensation during mating and ensuring reliable contact between terminals.
Implementation Method 1
Each of the receptacle terminals has a main contact point, a support contact point, and a resilient portion, wherein the resilient portion connects between the support contact point and the main contact point
Data Source
AI summary
A connector assembly comprises a plug connector and a receptacle connector. The receptacle connector includes a receptacle insulator and a row of receptacle terminals. Each of the receptacle terminals has a main contact point, a support contact point, and a resilient portion. The plug connector includes a plug insulator and a row of plug terminals. Each of the plug terminals has a main contact portion, a support contact portion, an insertion end portion, a contact difference and an additional contact difference. Under a mated state where the plug connector and the receptacle connector are mated with each other, the main contact points are in contact with the main contact portions while the support contact points are in contact with the support contact portions. The main contact portion of each of the plug terminals is flush with the support contact portion of the plug terminal adjacent thereto.