Stepped Termination Block for Compact Connector Assembly
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Solution Overview
Problem
The assembly of smaller connector inserts for electronic devices is complicated due to the need for precise trimming and soldering of conductors, which is difficult in smaller form factors.
Innovation Solution
A stepped termination block design that separates power and signal conductors into different rows, allowing for easier trimming and attachment to a printed circuit board, with the option of using a crimping piece for heat dissipation and a two-piece termination block for mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If connector inserts are made smaller to meet customer preferences for sleeker devices, then device size is reduced, but assembly complexity increases due to difficult trimming and soldering of conductors
Solution Approach 1:
The termination block is divided into multiple segments or sections, each designed to accommodate and guide specific conductors. This segmentation allows for organized conductor routing and simplifies the trimming and soldering processes by providing dedicated spaces for each conductor, thereby reducing assembly complexity despite smaller overall dimensions.
Solution Approach 2:
The termination block is designed with pre-formed conductor guides and positioning features that prepare conductors for trimming and soldering before the actual assembly process. This preliminary structuring of the termination block eliminates the need for complex manual alignment and positioning during assembly, making the process simpler even in compact connector inserts.
2Area of stationary object
If multiple conductors are arranged in a compact termination block, then space is saved, but trimming and soldering becomes more difficult
Solution Approach 1:
Different regions of the termination block are designed with locally optimized features tailored to specific conductor types and functions. For example, certain areas may have enhanced guiding structures, varying depths, or specialized positioning elements that facilitate easier trimming and soldering for conductors in those specific locations, thereby maintaining manufacturability despite compact overall dimensions.
Solution Approach 2:
The termination block utilizes three-dimensional spatial arrangement to organize conductors vertically and horizontally, rather than simply arranging them in a flat two-dimensional plane. This multi-dimensional organization provides adequate working space for trimming and soldering operations while maintaining a compact footprint, as conductors are distributed across multiple levels and planes within the termination block.
3Manufacturing precision
If conductors are closely spaced in smaller connector inserts, then miniaturization is achieved, but precision requirements for trimming and soldering increase
Solution Approach 1:
The termination block incorporates pre-formed conductor guides, positioning ribs, and alignment features that automatically establish precise conductor spacing and positioning during the assembly process. These preliminary structural elements eliminate the need for high-precision manual positioning and trimming operations, thereby achieving close conductor spacing without proportionally increasing assembly difficulty.
Solution Approach 2:
The termination block is designed with self-aligning and self-positioning features that automatically ensure precise conductor spacing and alignment during assembly. The structure itself provides the necessary guidance and constraints, eliminating the need for external fixtures or complex alignment procedures, thereby maintaining manufacturing precision while reducing assembly complexity.
Data Source
AI summary
Structures and methods that simplify the assembly of connector inserts. One example may provide a connector insert having a termination block that is arranged to receive an end of a cable. The termination block may provide a first number of conductors in a first row and a second number of conductors in a second row. The termination block may be stepped such that the first number of conductors emerge from the termination block at a different position along their lengths than the second number of conductors. The first number of conductors may then attach to a first side of a printed circuit board or other connector portion, while the second number of conductors may then attach to a second side of the printed circuit board or other connector portion.