Electrical Connector Contact Arrangement for Signal Speed
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Solution Overview
Problem
Current USB connectors, such as the USB 2.0 A type, face limitations in signal transmission speed, particularly when handling larger files like audio or video, as they often run out of bandwidth due to the Full Speed rate and lack of sufficient data transmission capacity.
Innovation Solution
The design introduces a new electrical connector with enhanced contact arrangements, featuring a first contact module with flat, solderable contacts and a second contact module with elastic, arc-shaped contacts, both insert molded within their respective housings, and covered by a metal shell, which increases transmission speed by accommodating differential signal contacts and improving assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If USB 2.0 connector with standard contact arrangement is used, then manufacturing simplicity is maintained, but signal transmission speed is insufficient for high-bandwidth applications
Solution Approach 1:
The contact arrangement is segmented into two distinct modules: a first contact module with flat contacts for power and ground connections, and a second contact module with elastic arc-shaped contacts for data transmission. This segmentation allows each module to be optimized independently for its specific function, enabling high-speed data transmission while maintaining manufacturing simplicity through modular assembly
Solution Approach 2:
The patent introduces a new dimensional arrangement by positioning the elastic contacts to extend along the length direction of the housing, creating a two-row arrangement along the inserting direction. This spatial reorganization increases transmission capacity without significantly increasing overall device complexity
2Productivity
If traditional contact insertion method is used, then assembly flexibility is maintained, but assembly efficiency and cost are reduced
Solution Approach 1:
The patent merges the contact holding function directly into the housing structure through insert molding. The first housing contains installed grooves that receive flat contacts, while the second housing contains receiving slots for elastic contacts. This integration eliminates separate assembly steps for inserting contacts into the housing, significantly improving assembly efficiency and reducing manufacturing cost
Solution Approach 2:
The housing structures are designed to self-secure the contacts through molded-in grooves and slots. The first housing's installed grooves automatically hold the flat contacts in position, while the second housing's receiving slots and protrusions automatically engage with the elastic contacts, eliminating the need for additional fastening operations
Data Source
AI summary
An electrical connector (100) defining an inserting port (10) for connecting a corresponding plug, includes a first contact module and a second contact module fixed with each other. The first contact module includes a first housing (1) and a number of first contacts (31) insert molded in the first housing (1). The first housing (1) has a tongue (12) extending into the inserting port (10). Each first contact (31) has a first contact portion (311) extending to a free end of the tongue (12). The second contact module includes a second housing (2) and a number of second contacts (32) insert molded in the second housing (2). Each second contact (32) has a second contact portion (321) extending out of the second housing (2). The second contact portions (321) extend to the tongue and offsetting with the first contact portion (311) along a length direction of the tongue (12).