Annular Flexible Connector Layout for Reliable High-Density Mating
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Solution Overview
Problem
Conventional high-density electrical connectors face challenges in aligning multiple groupings of electrical contacts reliably and efficiently, leading to misalignment and unreliable connections, and are difficult to manufacture cost-effectively.
Innovation Solution
An electrical connector design featuring a receptacle with a first annular flexible circuit board and electrical contacts, and a plug with a second annular flexible circuit board, where the flexible contacts are arranged in annular patterns to ensure physical contact and alignment, using staggered and angled contact ribs to facilitate secure connections, and a system that includes a tool to detect short circuits for proper mating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If planar rows of stacked electrical contact boards are used, then high-density electrical connection is achieved, but misalignment and unreliable connections occur between boards
Solution Approach 1:
The patent transitions from planar contact boards to annular (circular) contact patterns. The electrical contacts are arranged in concentric annular rings instead of flat stacked rows, allowing the plug and receptacle to align through rotational symmetry. This curved geometry provides a predictable datum reference that eliminates misalignment issues while maintaining high contact density.
Solution Approach 2:
The invention adds a rotational dimension to the contact arrangement. Instead of stacking contacts in linear three-dimensional rows, the contacts are distributed across two-dimensional annular patterns that can rotate into alignment. This dimensional transformation from linear stacking to radial arrangement solves the alignment problem while preserving high-density connectivity.
2Manufacturing precision
If multiple groupings of electrical contacts are aligned predictably, then reliable connections are achieved, but manufacturing complexity increases
Solution Approach 1:
The annular flexible circuit board serves multiple functions simultaneously: it provides the structural substrate, defines the alignment datum through its circular geometry, supports multiple contact groupings in concentric patterns, and enables rotational alignment. This multi-functionality reduces the need for separate alignment features and simplifies manufacturing while maintaining high precision.
Solution Approach 2:
The patent uses uniform annular patterns with evenly spaced contacts around concentric circles. This homogeneous distribution of contacts in regular geometric patterns simplifies manufacturing processes compared to irregular stacked arrangements, as it allows for standardized tooling and easier quality control while achieving precise alignment.
3Ease of manufacture
If conventional stacked contact boards are used, then manufacturing is simpler, but connection reliability deteriorates due to misalignment
Solution Approach 1:
The annular circular geometry of the contact patterns provides inherent rotational symmetry that serves as a self-aligning feature. During assembly, the circular patterns naturally guide the plug and receptacle into correct alignment, eliminating the need for complex mechanical alignment mechanisms. This curved geometric approach maintains manufacturing simplicity while dramatically improving connection reliability.
Data Source
AI summary
An electrical connector includes a receptacle and a plug. The receptacle includes a first annular flexible circuit board and first electrical contacts coupled to the first annular flexible circuit board, electrically isolated from each other, and arranged in at least one receptacle annular pattern. The plug includes a second annular flexible circuit board and second electrical contacts coupled to the second annular flexible circuit board, electrically isolated from each other, and arranged in at least one plug annular pattern. The plug is selectively connectable with the receptacle. When the plug is selectively connected with the receptacle, each one of the first electrical contacts of the receptacle is in physical contact with a corresponding one of the second electrical contacts of the plug.