Self-Adjusting Electrical Connector with Flexible Wire
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Solution Overview
Problem
Conventional electrical connectors are prone to damage due to misalignment during mating, leading to potential equipment malfunction and safety concerns, especially in complex systems with high signal density, and existing solutions that introduce flexibility compromise signal integrity.
Innovation Solution
A mated pair electrical connector design featuring a flexible wire and retaining ring system that allows self-adjustment during mating, maintaining electrical conductivity while accommodating misalignment without straining PCB connections, and utilizing a wire basket for force application to align components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional rigid PCB connections are used in electrical connectors, then structural stability is improved, but damage risk during misalignment increases
Solution Approach 1:
The connector is divided into two distinct portions: a rigid portion that maintains structural stability and provides rigid PCB connections, and a flexible portion that absorbs misalignment through elastic deformation. This segmentation allows each portion to fulfill its specific function without compromising the other.
Solution Approach 2:
Different portions of the connector are assigned different mechanical properties: the rigid portion (including PCB connection areas) maintains high stiffness for structural stability, while the flexible portion (including spring elements and flexible circuits) is designed with appropriate elasticity to accommodate misalignment. This local differentiation of mechanical properties resolves the contradiction between rigidity and damage resistance.
2Reliability
If spring elements are introduced to allow movement and self-alignment, then damage risk is reduced, but signal integrity deteriorates due to additional inductance and impedance matching complications
Solution Approach 1:
The spring elements are designed with specific geometric parameters (wire diameter, coil diameter, number of turns, pitch) that are optimized to minimize inductance while maintaining sufficient flexibility for misalignment accommodation. By carefully controlling these parameters, the negative impact on signal integrity is reduced.
Solution Approach 2:
The connector employs composite construction combining conductive materials (for electrical connections) with flexible structural materials (for misalignment accommodation). The spring elements use material compositions that balance electrical conductivity with mechanical flexibility, reducing both inductance and impedance matching issues while maintaining damage protection capabilities.
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 provides a robust, cost-effective, and reliable electrical connection with improved impedance matching and reduced risk of damage, enabling precise alignment tolerance and maintaining signal integrity across various configurations.
Implementation Method 1
a flexible wire connected to the inner pin, as well as a plug PCB end with a rear tail surrounding the flexible wire
Implementation Method 2
a wire basket disposed within the cavity and configured to engage the plug outer conductor and apply a force to the plug outer conductor for the moving of the plug outer conductor with respect to the rear tail
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A self-adjusting mated pair connector having a conductive flexible wire and a retaining ring to facilitate electrical connections through the mated pair connector. A receptacle assembly rigidly and electrically connects a portion of the receptacle assembly to a receptacle PCB. A plug assembly rigidly and electrically connects a portion of the plug assembly to a plug PCB. During mating of the receptacle assembly and the plug assembly, the flexible wire and retaining ring allow for floating or movement of a portion of the receptacle assembly and/or plug assembly without stressing or damaging the rigid electrical connections with the receptacle PCB and the plug PCB or the connector interfaces. Electrical conductivity can be maintained without needing to angle the entire receptacle assembly and/or plug assembly during misalignment in the mating process. Impedance matching and low inductance of the mated pair connector may allow for desired electrical performance.