Adaptive Connector Pivoting Contact Jack for Misalignment
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Solution Overview
Problem
Existing connectors fail to effectively compensate for misalignment between connection jacks or lamella devices, leading to unreliable electrical contacts, especially in applications with manufacturing tolerances and vibration.
Innovation Solution
The adaptive connector features a contact jack and lamella comb that are mechanically inseparable but movable, allowing for pivoting and translational movement within specific ranges to maintain contact and compensate for misalignment, and includes adapter elements with similar capabilities to connect counter connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If connectors are rigidly fixed to compensate for misalignment, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The contact jack is designed with pivoting capability around a pivot axis, transforming the rigid connector into a dynamic system that can adapt to misalignment through controlled rotation. This dynamic adjustment mechanism compensates for manufacturing tolerances without requiring overly complex rigid positioning structures.
Solution Approach 2:
The connector automatically compensates for misalignment through the inherent pivoting motion of the contact jack. The lamella comb's elastic deformation and the contact jack's rotation work together to self-adjust the connection, eliminating the need for external adjustment mechanisms or complex alignment systems.
2Device complexity
If the connector structure is simplified to reduce complexity, then device complexity is reduced, but reliability deteriorates due to inability to compensate misalignment
Solution Approach 1:
The contact jack pivots around a defined axis to maintain electrical contact despite misalignment between connectors. This simple rotational degree of freedom provides the necessary adaptability to ensure reliable contact without adding complex mechanical systems.
Solution Approach 2:
The contact jack changes its angular parameter (rotation angle around pivot axis) to adapt to misalignment conditions. The lamella comb also changes its deformation state, allowing the system to maintain electrical contact across varying alignment conditions while keeping the structure relatively simple.
3Adaptability or versatility
If the contact jack is made movable to accommodate misalignment, then adaptability is improved, but manufacturing precision requirements worsen due to moving parts
Solution Approach 1:
The contact jack is designed to pivot around a fixed pivot axis rather than requiring complex multi-axis movements. This single-degree-of-freedom rotation simplifies manufacturing tolerances compared to fully articulated mechanisms while still providing effective misalignment compensation.
Solution Approach 2:
The pivoting function is extracted as a distinct degree of freedom from the overall connector assembly. By separating the rotational adjustment capability into a specific pivoting motion around a defined axis, the design isolates the complexity to a manageable component with well-defined manufacturing requirements.
4Stability of the object's composition
If rigid connectors are used to maintain structural stability, then stability is improved, but adaptability deteriorates due to inability to pivot or move
Solution Approach 1:
The contact jack introduces controlled dynamics through pivoting motion around a pivot axis, allowing the otherwise stable connector assembly to adapt to misalignment. The lamella comb provides additional elastic compliance, creating a stable yet adaptable connection system.
Solution Approach 2:
The connector is segmented into distinct functional components: the rigid housing providing structural stability, the pivoting contact jack providing rotational adaptability, and the elastic lamella comb providing deformation compliance. This segmentation allows each component to optimize its properties without compromising the others.
Data Source
AI summary
An adaptive connector comprising a contact jack and a lamella comb, wherein the lamellae of the lamella comb electrically contact the contact jack, characterised in that the contact jack is connected in a mechanically inseparable but movable manner with the lamella comb. The contact jack can be pivoted relatively to the lamella comb with an angular range of more than 2 degrees while maintaining contact between the contact jack and the lamellae of the lamella comb, and/or the contact jack can be moved translationally relatively to the lamella comb in at least one direction within a translational range of more than 1 millimetre. Moreover, an adaptive connector comprising two or more adapter elements that are electrically separate from each other. Each adapter element comprises a connection jack or a connection lamella device at each of two ends of the adapter element, the connection jack or connection lamella device of one end being electrically connected to the connection jack or connection lamella device of the other end. The adapter elements are connected with each other in a mechanically inseparable but movable manner. Any of the adapter elements can be pivoted relatively to at least one other of the adapter elements with an angular range of more than 4 degrees and/or any of the adapter elements can be moved translationally relatively to any other of the adapter elements in at least one direction by more than 2 millimetre. Finally, a system comprising the adaptive connector and a counter connector.