Terminal Module Assembly Without Signal Terminal Cutting
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Solution Overview
Problem
The manufacturing process of terminal modules in electrical connectors is complex and prone to damage due to the need for precise cutting of signal terminals, which is difficult with smaller components and can increase costs.
Innovation Solution
A method of manufacturing terminal modules that involves forming signal and conductive terminals separately, aligning their soldering portions, and inserting electronic components without cutting, using insert-molding to create a plastic seat for precise alignment and soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a cutting blade is used to cut signal terminals through through holes to form breaks, then the terminal module can be manufactured with separate portions for electronic component connection, but the manufacturing process becomes complex and prone to damage when terminal modules are small in size
Solution Approach 1:
The patent divides the signal terminal into two separate parts: a first signal terminal and a second signal terminal, with each having its own soldering portion. This segmentation eliminates the need for cutting operations and allows each terminal to be independently positioned and soldered to the electronic component, thereby simplifying the manufacturing process while maintaining the ability to create the necessary breaks.
Solution Approach 2:
The patent performs preliminary positioning of the first and second signal terminals at their respective soldering portions before the soldering operation. The plastic fixing member is designed with positioning structures that pre-align the terminals, eliminating the need for complex cutting and repositioning operations during assembly.
2Volume of moving object
If the terminal module size is reduced to meet miniaturization requirements, then the connector becomes more compact, but the through holes become too small for cutting blade operation
Solution Approach 1:
By segmenting the signal terminal into separate first and second signal terminals, the patent eliminates the need for cutting operations within the miniaturized through holes. Each terminal can be independently positioned and soldered, making the process feasible even when the overall module size is reduced.
Solution Approach 2:
The patent replaces the mechanical cutting operation with a positioning and soldering system. Instead of using a cutting blade to create breaks through small holes, the design uses separately formed terminals with positioning structures that guide their placement, substituting mechanical cutting with a more suitable positioning-and-soldering approach for miniaturized components.
3Manufacturing precision
If precise positioning is not achieved during cutting operation, then the cutting blade may cut other portions of the terminal module, but achieving precise positioning increases manufacturing complexity
Solution Approach 1:
The patent segments the signal terminal into separate first and second signal terminals that are independently positioned at their respective soldering portions. This segmentation eliminates the risk of cutting adjacent terminals since no cutting operation is performed. The positioning structures in the plastic fixing member guide each terminal into its correct position before soldering.
Solution Approach 2:
The patent implements preliminary positioning of the signal terminals using positioning structures integrated into the plastic fixing member. This preliminary action ensures correct alignment before the soldering operation, eliminating the need for complex real-time positioning control during cutting and reducing manufacturing complexity.
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
Facilitates convenient manufacturing by eliminating the need for cutting and improves electrical characteristics through precise alignment and soldering of components.
Implementation Method 1
Performing insert-molding, in which the signal terminals and the ground terminals are arranged as embedded components in a cavity of an insert mold, and a plastic fixing member is formed by insert-molding
Implementation Method 2
Injecting molten plastic into the internal through holes by insert-molding or adhesive dispensing, and the molten plastic, after curing, forms a plastic layer covering the first electronic component
Implementation Method 3
Soldering a first electronic component on the break, such that the two separate portions of each signal terminal are electrically connected through the first electronic component
Data Source
AI summary
A method of manufacturing a terminal module and a connector assembly having the terminal module. The terminal module includes first signal terminals and conductive terminals formed individually. Each first signal terminal includes a first body portion, a first soldering portion and a tail portion. Each conductive terminal includes a second body portion, a contact portion and a second soldering portion. The conductive terminals include second signal terminals. The first soldering portion of each signal terminal and the second soldering portion of each second signal terminal are provided to be separate and form an interval therebetween, and an electronic component is provided at the corresponding interval, without the need to cut the middle portions of the signal terminals by a cutting blade to form a broken recess, thus being convenient for the manufacturing of the terminal module, and improving the electrical characteristics of the terminal module.