Concentric Annular Electrical Connector Alignment
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Solution Overview
Problem
Conventional high-density electrical connectors face challenges in aligning multiple contact boards reliably, leading to misalignment and unreliable connections due to unpredictable primary datum points.
Innovation Solution
The design features a plug and receptacle with concentric outer and inner contact annuli, resiliently flexible contacts, and a support ring, along with alignment and retention mechanisms, ensuring coaxial and rotational alignment of contacts for stable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional stacked electrical contact boards are used, then high-density electrical connection is achieved, but alignment reliability deteriorates due to unpredictable primary datum points
Solution Approach 1:
The connector is divided into two separate components: a plug component containing first electrical contacts and a receptacle component containing second electrical contacts. This segmentation allows each component to be independently manufactured and assembled with their own datum points, eliminating the cumulative alignment errors that occur when stacking multiple contact boards. The plug and receptacle are then mated together to form the complete high-density connector assembly.
Solution Approach 2:
The electrical contacts are arranged in a three-dimensional configuration with concentric annular patterns at different radial distances from a central axis. This multi-dimensional arrangement (concentric annuli at different radii) allows for high contact density while maintaining predictable alignment through a single primary datum point at the central axis, avoiding the need to stack multiple two-dimensional contact boards.
2Quantity of substance
If multiple contact boards are stacked to achieve high density, then electrical contact quantity increases, but manufacturing precision deteriorates due to cumulative alignment tolerances
Solution Approach 1:
The connector is divided into two separate components: a plug component containing first electrical contacts and a receptacle component containing second electrical contacts. This segmentation allows each component to be independently manufactured and assembled with their own datum points, eliminating the cumulative alignment errors that occur when stacking multiple contact boards. The plug and receptacle are then mated together to form the complete high-density connector assembly.
Solution Approach 2:
The electrical contacts are arranged in a three-dimensional configuration with concentric annular patterns at different radial distances from a central axis. This multi-dimensional arrangement (concentric annuli at different radii) allows for high contact density while maintaining predictable alignment through a single primary datum point at the central axis, avoiding the need to stack multiple two-dimensional contact boards.
3Reliability
If resiliently flexible contacts are used, then alignment compensation is improved, but device complexity increases
Solution Approach 1:
The electrical contacts are designed with resiliently flexible properties, allowing them to elastically deform and compensate for minor misalignments between the plug and receptacle components. This parameter change (introducing flexibility) enables the contacts to self-adjust during mating, ensuring reliable electrical connection without requiring complex active alignment mechanisms or precision control systems.
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 configuration ensures predictable alignment and reliable high-density electrical connections by bypassing housing alignment tolerances and using flexible contacts to maintain angular and radial positioning, reducing misalignment and enhancing connection stability.
Implementation Method 1
The first electrical contacts of the first outer contact annulus are resiliently flexible away from the central axis of the plug. The first electrical contacts of the first inner contact annulus are resiliently flexible toward the central axis of the plug.
Data Source
AI summary
Disclosed herein is an electrical connector, comprising a plug and a receptacle. The plug comprises first electrical contacts electrically isolated from each other and arranged into a first outer contact annulus and a first inner contact annulus concentric with and radially spaced apart from each other. The receptacle comprises second electrical contacts electrically isolated from each other and arranged into a second outer contact annulus and a second inner contact annulus concentric with and radially spaced apart from each other. The plug is selectively connectable with the receptacle. When the plug is selectively connected with the receptacle, each of the first electrical contacts of the first outer contact annulus is in physical contact with a corresponding one of the second electrical contacts of the second outer contact annulus and each of the first electrical contacts of the first inner contact annulus is in physical contact with a corresponding one of the second electrical contacts of the second inner contact annulus.