Connector Armor Deformation Isolation via Segmented Base
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Solution Overview
Problem
The existing connector designs face reliability issues during mating due to deformation of the armor portion, which can prevent the power terminal from making contact with the projection, leading to reduced connection reliability between the connector and the mating connector.
Innovation Solution
A connector design featuring a housing with a receiving portion, an additional member with a fixed portion, a base portion, an armor portion, a spring portion, and a projection, where the spring portion is partially covered by the armor portion, and the projection is located within the receiving portion, ensuring that the projection remains stable and in contact with the mating connector even when the armor is deformed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the armor portion is designed to receive the mating connector during mating, then the mating process is facilitated, but the armor portion may be deformed which causes the spring portion and projection to move, reducing connection reliability
Solution Approach 1:
The additional member is segmented into distinct functional portions: the armor portion (54) that receives the mating connector, the spring portion (56) that provides resilient support, and the projection (58) that makes contact. This segmentation allows the armor portion to deform during mating without transmitting that deformation to the spring portion and projection, which are positioned at a distance from the armor portion. The base portion (50) acts as a stable foundation that anchors both the armor and spring portions, enabling the armor to absorb mating forces independently.
Solution Approach 2:
The base portion (50) serves as an intermediary element that connects the armor portion (54) to the fixed portion (52) while providing a stable mounting point for the spring portion (56). When the armor portion deforms during mating, the base portion acts as a buffer that prevents this deformation from directly affecting the spring portion and projection, thereby maintaining connection reliability while still allowing the mating process to proceed.
2Stability of the object's composition
If the spring portion is positioned closer to the armor portion to improve structural stability, then the armor can be better supported, but the projection may be affected by armor deformation during mating
Solution Approach 1:
The additional member is divided into functionally independent segments: the armor portion (54) for receiving the mating connector, the base portion (50) for providing stable support, and the spring portion with projection (56, 58) for making contact. This segmentation allows the armor portion to be positioned close to the base for structural stability while the spring portion is positioned at a distance to avoid deformation effects, achieving both structural stability and connection reliability simultaneously.
3Ease of operation
If the projection is positioned within the receiving portion to ensure contact with the mating connector, then electrical connection is facilitated, but the projection may be affected by armor deformation
Solution Approach 1:
The base portion (50) acts as an intermediary that anchors the spring portion (56) at a position where the projection (58) can be located within the receiving portion (22) for easy electrical connection, while the base itself is positioned to be unaffected by armor deformation. This intermediary positioning allows the projection to be in the correct location for contact while being supported by a stable foundation that isolates it from deformation forces.
4Reliability
If the armor portion is made more rigid to prevent deformation during mating, then connection reliability is improved, but the mating process becomes more difficult as the armor cannot accommodate the mating connector
Solution Approach 1:
The additional member is segmented so that only the armor portion (54) is designed to be deformable for easy mating, while the base portion (50) and the spring portion with projection (56, 58) are positioned to maintain their structural integrity. This segmentation allows the armor to be flexible during mating while the contact elements remain stable, achieving both ease of mating and connection reliability.
Solution Approach 2:
Different portions of the additional member have different mechanical properties: the armor portion (54) is designed with local deformability to facilitate mating, while the base portion (50) and spring portion (56) are positioned to maintain local stability. This local differentiation of mechanical properties allows the armor to accommodate the mating connector while the projection maintains reliable contact.
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 design enhances the connection reliability by maintaining the projection's contact with the mating connector, even under deformation of the armor portion, thereby ensuring consistent electrical connection.
Implementation Method 1
The spring portion (56) extends from the base portion (50). The projection (58) is supported by the spring portion (56) and projects inward in the lateral direction (Y-direction).
Implementation Method 2
When the additional member (40) is seen from above along the upper-lower direction (Z-direction), the spring portion (56) is, at least in part, covered by the armor portion (54).
Data Source
AI summary
A connector is mountable on an object in an upper-lower direction and mateable with a mating connector along the upper-lower direction. The connector comprises a housing and an additional member held by the housing. The housing has a receiving portion for receiving the mating connector. The additional member has a fixed portion fixed to an object, a base portion which extends upward from the fixed portion and is located outside the receiving portion in a lateral direction, an armor portion extending inward from the base portion in the lateral direction, a spring portion extending from the base portion and a projection which is supported by the spring portion and projects inward in the lateral direction. The extending of the spring portion from the base portion starts at a starting portion which is nearer to the fixed portion than to the innermost part of the armor portion.