Staggered Leadframe Assembly for Electrical Connectors
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Solution Overview
Problem
Existing leadframe assemblies require different configurations to achieve desired mating sequences, leading to increased manufacturing complexity and costs due to the need for distinct designs for each sequence, whereas a single configuration is desired to produce various mating sequences.
Innovation Solution
A connector housing design that allows identical leadframe assemblies to be arranged in a specific manner within the housing, using dovetail receptacles and protrusions to create different mating sequences without altering the leadframe assembly configuration, enabling a single leadframe assembly configuration to produce multiple connector mating sequences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different leadframe assembly configurations are used to produce desired mating sequences, then the mating sequence requirements are met, but the manufacturing complexity and costs increase due to the need for distinct designs
Solution Approach 1:
The patent applies universality by designing a single standardized leadframe assembly configuration that can be used across multiple connector positions to produce different mating sequences. Instead of creating distinct leadframe designs for each mating sequence requirement, the same leadframe assembly is universally applied and differentiated through its position and staggering arrangement within the connector housing, thereby reducing design complexity while maintaining adaptability.
Solution Approach 2:
The patent resolves the contradiction by shifting from varying leadframe assembly configurations (one-dimensional design variation) to varying the positional arrangement and staggering of identical leadframe assemblies within the connector housing (spatial dimensionality). By controlling which leadframe assemblies are staggered relative to others in the mating direction, different mating sequences are achieved without changing the leadframe assembly design itself.
2Device complexity
If a single leadframe assembly configuration is used to produce various mating sequences, then manufacturing complexity is reduced, but the ability to achieve precise mating sequences may be limited
Solution Approach 1:
The patent applies dynamics by making the mating sequence adjustable through the selective staggering of leadframe assemblies. The same leadframe assembly configuration can dynamically produce different mating sequences by changing which assemblies are positioned to extend farther in the mating direction, allowing the system to adapt to different sequence requirements without physical redesign.
Solution Approach 2:
The patent segments the connector into multiple identical leadframe assembly units that can be independently positioned and staggered. By dividing the connector into discrete, interchangeable modules with the same design, the system achieves versatility through combinatorial arrangement rather than through complex individual component design.
3Ease of operation
If contacts of different lengths are employed to produce a multi-tiered mating sequence, then the desired mating sequence is achieved, but the need for different leadframe assemblies increases design and manufacturing complexity
Solution Approach 1:
The patent makes the leadframe assembly universal by using identical contact length configurations across all assemblies. The same standardized leadframe design serves multiple functions by being positioned in different staggered arrangements, eliminating the need to manufacture specialized leadframe assemblies with varied contact lengths for different mating sequence requirements.
Solution Approach 2:
The patent uses copying by replicating the same leadframe assembly design multiple times and arranging them in different staggered positions. Instead of creating unique designs for each mating sequence, identical copies of the leadframe assembly are produced and strategically positioned to achieve the desired multi-tiered mating sequence, simplifying manufacturing while maintaining operational control.
Data Source
AI summary
An electrical connector may include a connector housing and a plurality of identical leadframe assemblies received in the connector housing. Each of the leadframe assemblies may define a leadframe mating sequence. The leadframe assemblies may be arranged relative to one another to define a connector mating sequence that differs from the leadframe mating sequence. Each leadframe assembly may define a leadframe mounting footprint. The leadframe assemblies may be arranged relative to one another such that the leadframe mounting footprints are staggered, i.e., offset relative to one another.