High-Density Connector Plug With Stepped Welding Area
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Solution Overview
Problem
Existing connector plugs have a large interface footprint and low pin density, and the connection method via press fit often results in warped contacts, limiting reliability and preventing welding connections.
Innovation Solution
A high-density connector plug design with a stepped welding area and flanged edges on contacts, allowing for increased pin density and visible welding, utilizing a pull-welding process to improve efficiency and prevent solder flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a conventional connector plug design is used, then the interface footprint is large, but the pin density is low
Solution Approach 1:
The patent transitions from a single-plane contact arrangement to a multi-level stepped structure. The first and second stepped structures create vertical layering, allowing contacts to be arranged in multiple planes. This dimensional change enables higher pin density within a reduced footprint by utilizing three-dimensional space efficiently.
Solution Approach 2:
The connector plug is divided into segmented stepped structures (first and second stepped structures) with distinct levels. Each stepped structure contains multiple contacts arranged in specific patterns, allowing independent optimization of each segment. This segmentation enables dense packing of contacts while maintaining manageable assembly and wiring organization.
2Reliability
If press fit connection method is used, then assembly is simple, but contacts become warped affecting reliability
Solution Approach 1:
The patent extracts the connection method from simple press-fit to a more sophisticated multi-step process involving positioning structures and controlled insertion. The stepped structures and positioning features are removed from the conventional simple insert design, requiring a more elaborate assembly process that prevents contact warping through controlled positioning and reduced mechanical stress.
3Reliability
If welding connection is implemented, then connection reliability improves, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates preliminary positioning structures (stepped structures, positioning features) that prepare the contacts for welding before the actual welding process. These pre-positioning elements ensure accurate alignment and proper spacing, making the subsequent welding operation more reliable and consistent. The complexity is front-loaded in the structure design rather than the welding process itself.
4Quantity of substance
If contact spacing is reduced to increase pin density, then more contacts fit in smaller area, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies different spacing configurations to different regions of the connector. The stepped structures create zones with varying contact densities and spacing requirements. This local differentiation allows tight spacing where needed while maintaining larger spacing in other areas for manufacturing tolerance and heat dissipation, optimizing the balance between pin density and manufacturing precision.
Data Source
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AI summary
The present invention relates to a high density connector plug (20), comprising the body of plug and a plastic enclosure (23) for fixing said body of plug and being connected with the cable. Said body of plug comprises a shielding shell (21), an insulator (24) mounted in said shielding shell (21), and a set of contacts provided on the side of said insulator (24); said insulator (24) comprising a base (241) and upper plastic body (242) and lower plastic body (243) extending outwards from one side of said base (241), which have slots (244) for mounting said contacts. Thus the interface footprint of plug (20) and socket (40) is reduced and the pin density is increased, thereby the volume of the corresponding device is significantly reduced, so that the devices have a trend towards miniature and high density. In addition, there is a stepped welding area provided on the insulator, so that the contacts can be connected to the cable by welding, and there is visibility in the cable welding, thereby the working efficiency is improved.