Electrical Connector Floating Insulator Vibration Resistance
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Solution Overview
Problem
Existing electrical connectors face challenges in achieving both space-saving and high vibration resistance while enabling floating of parts, as thinner walls are required for space-saving but thicker walls are needed for vibration resistance, and the use of snaked or curved contacts to achieve elasticity increases the width dimension, contradicting these requirements.
Innovation Solution
The electrical connector design includes a plug connector and a receptacle connector with snaked elastic portions in the plug contacts, supporting an insulator in a floating state, allowing for a thickness increase in the housing to enhance vibration resistance while maintaining a width dimension of 5 mm or less, enabling line contact between plug and receptacle contacts and optimizing the arrangement of elastic portions for space-saving and floating functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the width dimension is reduced to achieve space-saving, then the connector becomes more compact, but the housing wall thickness must be reduced which deteriorates vibration resistance
Solution Approach 1:
The patent resolves the contradiction by shifting the design focus from the width dimension to the height dimension. The housing wall thickness in the height direction is increased to enhance vibration resistance, while the width dimension is minimized through optimized contact arrangement and floating insulator design. This dimensional redistribution allows the connector to achieve both compact width (5mm or less) and sufficient vibration resistance through thicker walls in the vertical direction.
2Reliability
If snaked or curved contacts are used to provide elasticity for floating function, then the floating capability is achieved, but the width dimension increases
Solution Approach 1:
The patent applies curvature to the elastic portion of the contacts, using a snake-like curved configuration that provides the necessary elasticity for the floating function. The curved design allows the contacts to deform elastically under vibration, maintaining electrical connection while enabling the insulator to float. This curved elastic portion is strategically positioned within the housing to achieve the floating capability without excessively increasing the overall width dimension.
Solution Approach 2:
The patent implements a dynamic floating mechanism where the insulator can move relative to the housing through the elastic deformation of the contacts. The floating insulator design allows the connector to adapt to vibrations and misalignments dynamically, maintaining reliable electrical connection. The elastic portions of the contacts provide the necessary compliance, enabling the system to respond to external vibrations while maintaining contact pressure.
3Reliability
If two insulators are used to achieve floating function, then the floating capability is provided, but the device complexity and width dimension increase
Solution Approach 1:
The patent extracts and eliminates the locator component from the connector structure, integrating its functions into the housing and contacts. By removing this separate insulating component, the design reduces the number of parts and simplifies the overall structure while maintaining the floating capability through the elastic contacts and single insulator configuration. This extraction principle directly reduces device complexity and width dimension.
Solution Approach 2:
The housing is designed to perform multiple functions: it provides structural support, contains the elastic contacts, and enables the floating mechanism through its interaction with the insulator. The housing structure is optimized to allow vertical movement of the insulator while maintaining lateral stability, combining several functions into a single component rather than requiring separate dedicated parts for each function.
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 achieves a saved space of 3 mm compared to prior art, improved vibration resistance, and allows for floating movements of 0.2 to 0.5 mm, providing superior vibration-proof characteristics and reduced overall height.
Implementation Method 1
each of the plug contacts (56) is provided between the second and third fixed portions (60, 62) with an elastic portion (66) having at least one snaked portion
Data Source
AI summary
An electrical connector consists of a plug connector and a receptacle connector to be fitted. An insulator is supported only by plug contacts each provided between second and third fixed portions with an elastic portion having at least one snaked portion so as to be floating in a housing. The shape of the second contact portion of each of the plug contacts is substantially in the form of a plate-shaped piece so that the second contact portion of the plug contact and the first contact portion of a receptacle contact are caused to contact each other in line contact at one location, and the elastic portion is arranged within a range from a position below the second contact portion to a position below the insulator. The electrical connector thus constructed is superior in resistance to vibration, and achieves space-saving and floating of the insulator.