Blind Mate Connector Float Assembly for Tolerance Misalignment
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Solution Overview
Problem
In electronic assemblies with limited space, existing connectors are cumbersome and costly to replace, and tolerance issues often cause misalignment, leading to mechanical and electrical coupling challenges.
Innovation Solution
A blind mate connector assembly featuring a first and second manifold with connector cavities and a mechanical float mechanism, allowing right-angle cable connectors to move in multiple degrees of freedom and rotation, facilitating alignment and easy replacement of connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional electrical connectors are used in limited space electronic assemblies, then mechanical and electrical coupling is achieved, but the connectors are cumbersome and difficult to replace
Solution Approach 1:
The connector assembly is divided into separate modules: a reusable manifold assembly and replaceable cable connector assemblies. This segmentation allows the complex manifold to be manufactured once and reused, while simpler connector modules can be easily replaced individually without affecting the entire assembly.
Solution Approach 2:
The cable connector assemblies are extracted as separate, removable units from the manifold. Each connector can be independently removed and replaced by detaching it from the manifold, simplifying the replacement process and reducing the time and cost associated with connector replacement.
2Manufacturing precision
If traditional fixed-position connectors are used, then mechanical coupling is achieved, but tolerance issues cause misalignment between electronic assemblies
Solution Approach 1:
The connector assembly incorporates a mechanical float mechanism with biasing devices that allow the connector to dynamically adjust its position. The biased connector can float or move within a range of motion, enabling it to self-align with mating connectors despite manufacturing tolerances and misalignment issues.
Solution Approach 2:
The system changes the positional parameter of the connector through the float mechanism. The connector's position is no longer fixed but can vary within a controlled range, allowing it to adapt to different alignment conditions while maintaining reliable electrical and mechanical coupling.
3Area of stationary object
If low-profile connections are implemented to save space, then area is reduced, but connector replacement becomes more difficult
Solution Approach 1:
The low-profile connector maintains its compact form factor while being segmented into a reusable manifold and replaceable connector modules. This segmentation allows the compact design to be preserved while enabling easy replacement of individual connector modules without requiring access to the entire assembly.
Solution Approach 2:
The cable connectors are extracted as separate modules that can be independently removed from the low-profile manifold. This extraction maintains the space-saving low-profile design while allowing individual connectors to be replaced by simply detaching them from the manifold, making repair and maintenance easier despite the compact size.
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
This solution enables low-profile, efficient, and cost-effective electrical and mechanical connections between electronic assemblies, accommodating misalignment issues and simplifying the replacement process of connectors.
Implementation Method 1
a mechanical float mechanism at least comprising a biasing device and each connector cavity being sized larger than a respective one of the right angle cable connectors to facilitate movement of the one right angle cable connector in at least three linear degrees of freedom and some amount of rotational movement
Data Source
Figure 1
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AI summary
A blind mate connector assembly comprises a first manifold and a second manifold removably coupled to the first manifold that defines a connector housing positionable between a primary electronics assembly and a secondary electronics assembly. A plurality of connector cavities are defined between the first and second manifolds. A plurality of right angle cable connectors, each situated within one of the plurality of connector cavities, extend partially through the connector housing to facilitate blind mate connection between the primary electronics assembly and the secondary electronics assembly. The connector housing comprises at least one mechanical float mechanism configured to facilitate movement of each right angle cable connector in multiple degrees of freedom. The connectors are replaceable by disassembling the first and second manifolds.