Electrical Connector Contact Area Geometry Enlargement
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Solution Overview
Problem
Existing electrical connectors require material reduction in the forming die to achieve different thicknesses for signal and ground contacts, leading to higher material costs and the need for redesigning the mating connector, which is not tooling friendly.
Innovation Solution
The electrical connector features a male termination end with a slot between two beam sections, where material is removed between the beams and then deformed outwardly, allowing the use of thinner sheet metal for both signal and ground contacts to mimic thicker contacts, maintaining compatibility with existing connectors without material reduction in the die.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If material reduction in the forming die is used to achieve different thicknesses for signal and ground contacts, then the contact thickness can be varied, but material costs increase and the process is not tooling friendly
Solution Approach 1:
The ground contact is segmented into two separate beams instead of being a single solid piece. This segmentation allows the ground contact to achieve an equivalent thickness effect without requiring material reduction in the forming die, thereby maintaining tooling friendliness and reducing material costs while still providing the necessary electrical and mechanical properties
Solution Approach 2:
Instead of varying thickness in the vertical dimension through material reduction, the invention uses the horizontal dimension by creating a dual-beam structure. The two beams are positioned side-by-side to provide the necessary electrical isolation and mechanical support, achieving the functional equivalent of thickness variation without actually reducing material in the forming process
2Shape
If material reduction in the forming die is used to achieve different thicknesses, then contact geometry can be differentiated, but material costs increase
Solution Approach 1:
By segmenting the ground contact into two beams, the invention achieves differentiated contact geometry without requiring material reduction. The dual-beam structure provides the necessary geometric differentiation for proper mating connector engagement while using the full thickness of the sheet material, thereby reducing material costs
Solution Approach 2:
The invention changes the geometric parameter from thickness variation to width variation. Instead of making one contact thinner by removing material, the ground contact is made wider by adding a second beam, achieving the same functional differentiation through a parameter change that does not increase material costs
3Adaptability or versatility
If signal contacts are made thinner by material reduction, then they can mate with existing connectors, but redesigning the mating connector is required
Solution Approach 1:
Instead of making the signal contact thinner to match the mating connector, the invention inverts the approach by making the ground contact wider with a dual-beam structure. This inversion allows both signal and ground contacts to maintain the same thickness and mate with existing connectors without requiring redesign, while still achieving the necessary electrical and mechanical differentiation
Solution Approach 2:
The dual-beam ground contact structure serves multiple functions: it provides electrical isolation between signal contacts, maintains mechanical support for the mating connector, and ensures proper engagement without requiring different thicknesses. This multi-functionality allows universal compatibility with existing connectors while avoiding the need for redesign
Data Source
AI summary
A method including providing a contact lead frame comprised of a sheet metal member, where the contact lead frame includes a plurality of first signal contacts and a plurality of second ground contacts, where the first signal contacts have a male termination end with a first effective thickness which is substantially the same as thickness of the sheet metal member, and stamping a male termination end of the second ground contact, located at a same side of the lead frame as the male termination end of the first signal contacts, to form a dual beam structure having a second effective thickness which is larger than the first effective thickness, where two beams of the dual beam structure are generally parallel to each other along a majority of length of the male termination end of the second ground contact.