Ultra-Thin Connector Structure for Compact Fast Assembly
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Solution Overview
Problem
Conventional connectors cannot meet the requirements for use in ultra-thin spaces due to their size and assembly complexity.
Innovation Solution
An ultra-thin connector design featuring a dual-plane structure with a board end and wire end that are buckled together, incorporating elastic terminals and dual contact terminals, and a protective cover to minimize volume and enhance assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional connector structures are used, then assembly is straightforward, but the connector volume is too large for ultra-thin spaces
Solution Approach 1:
The wire end housing is nested inside the board end housing cavity, creating a compact layered structure. The protective cover is nested over the wire rods, and the dual contact terminals are arranged within the wire end housing. This nesting arrangement compresses the connection space and significantly reduces the overall connector volume to enable ultra-thin applications.
Solution Approach 2:
The connector adopts a dual-plane structure where contact terminals are arranged in two different planes (board end plane and wire end plane). This dimensional arrangement allows for more efficient space utilization and reduces the connector's volume while maintaining all necessary connection points.
2Productivity
If conventional connector structures are used, then assembly is simple, but assembly speed is slow
Solution Approach 1:
The elastic terminals are pre-installed on the board end housing, and the dual contact terminals are pre-installed on the wire end housing before final assembly. The locking structures are pre-formed on both housings. This preliminary arrangement of components simplifies the final assembly process and significantly increases assembly speed.
Solution Approach 2:
The elastic terminals provide self-springing contact force without requiring additional fastening mechanisms. The locking structures automatically engage when the wire end housing is inserted into the board end housing cavity, enabling self-assembly without complex fastening operations.
3Volume of moving object
If connector volume is reduced, then space constraint is satisfied, but assembly complexity increases
Solution Approach 1:
The elastic terminals automatically provide contact pressure through their springing action, eliminating the need for additional fastening or adjustment operations. The locking structures on both housings automatically engage when components are assembled, providing self-securing without complex assembly steps despite the compact volume.
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
The design significantly reduces connector volume, facilitates assembly, and ensures stable connections, making it suitable for space-constrained environments.
Implementation Method 1
an included angle is always maintained between the fixed end and the elastic end, so that the elastic terminal and the dual contact terminal are always in contact with each other
Implementation Method 2
the board end and the wire end are fixed to each other in a buckled manner
Data Source
AI summary
Disclosed is an ultra-thin connector, including a main body, and the main body includes a board end and a wire end. The board end includes a board end housing, a cavity is formed in the board end housing, elastic terminals are arranged on opposing sides inside the cavity, and first locking structures for fastening the wire end are arranged on other opposing sides inside the cavity. The wire end includes a wire end housing buckled with the first locking structures, a protective cover fastened to the wire end housing, wire rods partly wrapped by the protective cover, and dual contact terminals with A and B contact ends. Second locking structures fastened to the protective cover are arranged on opposing sides inside the wire end housing. The preset disclosure has a compact structure.