Annular Electrical Connector Alignment for High-Density Contacts
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Solution Overview
Problem
Conventional high-density electrical connectors face challenges in aligning multiple groups of electrical contacts predictably and efficiently, leading to misalignment and unreliable connections due to unpredictable primary datums in stacked electrical contact boards.
Innovation Solution
An electrical connector design featuring a first and second connector element with annular flexible circuit boards and flexible electrical contacts, where the second connector element's contacts have a movable portion angled outwardly, allowing for precise alignment and contact with corresponding contacts in the first element, facilitated by central engagement elements and housings with aligned openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional stacked electrical contact boards are used, then high-density electrical connections are achieved, but misalignment and unreliable connections occur due to unpredictable primary datums
Solution Approach 1:
The connector is divided into separate plug and receptacle elements, each with its own annular flexible circuit board. This segmentation allows each element to be manufactured and assembled independently with precise alignment features, eliminating the cumulative alignment errors that occur with stacked boards.
Solution Approach 2:
The patent transitions from a planar stacked arrangement to a three-dimensional annular configuration. The electrical contacts are arranged in concentric annular patterns on flexible circuit boards that can be radially compressed and expanded, enabling precise alignment through radial deformation rather than relying solely on planar stacking precision.
2Quantity of substance
If conventional stacked electrical contact boards are used, then high-density electrical connections are achieved, but manufacturing becomes costly and inefficient
Solution Approach 1:
The annular flexible circuit boards are pre-assembled with electrical contacts in their final configured positions before insertion into the connector housing. The central engagement element and aligned openings are also prepared in advance, enabling rapid assembly without complex alignment procedures during final assembly.
Solution Approach 2:
The radially compressible and expandable annular flexible circuit boards self-align during assembly through their elastic deformation characteristics. When the plug and receptacle are mated, the flexible boards automatically adjust their radial dimensions to ensure precise contact alignment, eliminating the need for complex external alignment mechanisms.
3Reliability
If flexible electrical contacts with movable portions are used, then precise alignment and reliable connections are achieved, but device complexity increases
Solution Approach 1:
The electrical contacts are formed as flexible metallic strips or springs integrated into the annular flexible circuit board. These thin, flexible contact elements can elastically deform to accommodate minor misalignments and maintain reliable electrical contact, while their simplicity reduces overall device complexity compared to rigid mechanical adjustment mechanisms.
Data Source
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AI summary
An electrical connector includes a first connector element and a second connector element. The first connector element includes a first annular flexible circuit board and first electrical contacts coupled to the first annular flexible circuit board in at least one first annular pattern. The second connector element includes a leading end and second electrical contacts. Each one of the second electrical contacts is a flexible electrical contact that includes a fixed portion directly attached to the second annular flexible circuit board and a movable portion that is movable relative to the fixed portion. The movable portion is radially outwardly angled away from the leading end of the second connector element. Each one of the first electrical contacts of the first connector element is in physical contact with a corresponding one of the second electrical contacts of the second connector element.