Connector Alignment Assembly for Fragile Pins
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Solution Overview
Problem
The fragility of male electrical connection pins makes them susceptible to damage during handling, transport, and mating, which is exacerbated by the increasing density of connections required in smaller electrical devices.
Innovation Solution
A connector alignment assembly featuring a support member with guide posts and compression mechanisms that transition from an uncompressed to a compressed position, allowing an alignment plate to position male connector pins in a spaced relationship, protecting the pins from damage by engaging either their tip or base regions depending on the compression state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the density of electrical connection terminals is increased to reduce device size, then the number of connections per unit area increases, but the male connection pins become more susceptible to damage such as bending or breaking
Solution Approach 1:
The patent applies beforehand cushioning by introducing a protective alignment plate with recesses that cradle the male connection pins before damage can occur. The plate is positioned between the pins and external forces, providing pre-emptive protection during handling and transport operations.
Solution Approach 2:
The alignment plate serves as an intermediary element between the male connection pins and the external environment. It mediates the interaction by providing a protective interface that prevents direct contact between the fragile pins and potential damage sources during handling and assembly operations.
2Reliability
If the male connection pins are made taller to ensure proper engagement, then the connection reliability improves, but the pins become more fragile and susceptible to damage during handling
Solution Approach 1:
The protective alignment plate with its specially designed recesses provides beforehand cushioning for the tall male connection pins. The recesses are dimensioned to perfectly cradle the pins, preventing bending or breaking during handling while allowing the pins to maintain their necessary height for reliable engagement.
Solution Approach 2:
The alignment plate applies local quality protection by providing customized recesses at specific locations corresponding to each male connection pin. Each recess is tailored to the local geometry and vulnerability of the pin it protects, offering targeted support where it is most needed without affecting other parts of the connector assembly.
3Quantity of substance
If the male connection pins are made thinner to reduce space, then the connection density increases, but the pins become more fragile and prone to damage
Solution Approach 1:
The alignment plate provides beforehand cushioning specifically designed for thin male connection pins. The recesses in the plate are precisely dimensioned to cradle the thin pins, preventing them from bending or breaking during handling while allowing the pins to maintain their thin profile for high connection density.
Solution Approach 2:
The alignment plate acts as an intermediary protective structure between the thin male connection pins and external forces. It provides a mechanical buffer that compensates for the reduced inherent strength of the thin pins, allowing high connection density without sacrificing damage resistance.
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
The solution effectively protects the male connector pins from bending or breaking by constraining their tip regions in the uncompressed state and aligning misaligned pins, ensuring reliable connections while maintaining high connection density.
Implementation Method 1
compression mechanisms, one associated with each of said plurality of guide posts. Each of the plurality of compression mechanisms is adapted to transition from the uncompressed position to a compressed position
Data Source
AI summary
A connector alignment assembly comprises a support member having a surface from which an array of male connector pins extend outwardly, each male connector pin having a base region proximate the surface of the support member and a tip region proximate the end of each male connector pin. Guide posts extend from the surface in the direction of the array of male connector pins and compression mechanisms, one associated with each of the guide posts. The compression mechanisms are adapted to transition from the uncompressed position to a compressed position. An alignment plate has guide holes which engage with the guide posts to position the alignment plate in a spaced relationship from the surface of the support member. The alignment plate has an array of male connector pin holes which engage with the array of male connector pins.