Connector Assembly With Offset Sheet Metal Contacts
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Solution Overview
Problem
Existing bladed connectors for electrical devices are large, bulky, and limited in their ability to efficiently pass current to multiple printed circuit boards, failing to meet the increasing power demands of smaller, more complex devices.
Innovation Solution
A connector assembly featuring a housing with sheet metal contacts that include battery contact regions and internal contact regions, which are offset in different spatial planes to facilitate connections to various electrical components, allowing for flexible alignment and high current flow, and a two-piece sheet metal contact design for improved flexibility and current flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If bladed connectors are attached directly to a printed circuit board, then current can be passed from the battery to the printed circuit board, but the connectors become large and bulky
Solution Approach 1:
The sheet metal contacts are bent at angles to extend into different spatial planes, allowing multiple contact regions to be positioned at different heights and orientations. This three-dimensional arrangement enables the connector to reach multiple PCBs and electrical components without requiring a larger overall connector volume, thus resolving the contradiction between current flow capability and connector size.
Solution Approach 2:
The connector assembly is divided into multiple sheet metal contacts, each with distinct battery contact regions and internal contact regions. This segmentation allows each contact to be independently configured to reach specific electrical components, enabling efficient current distribution to multiple PCBs while maintaining a compact connector structure.
2Power
If bladed connectors are attached directly to a printed circuit board, then current can be passed from the battery, but the connectors can only facilitate passing of current to a single printed circuit board
Solution Approach 1:
The sheet metal contacts are designed with multiple internal contact regions that can simultaneously or selectively contact different electrical components and PCBs. This multi-functional design allows a single connector assembly to serve multiple connection purposes, enabling current to be distributed to various electrical components within the device rather than being limited to a single PCB.
Solution Approach 2:
By extending sheet metal contacts into different spatial planes through bending at various angles, the connector can reach electrical components positioned at different locations and orientations. This spatial versatility enables the same connector structure to adapt to different device configurations and connection requirements.
3Adaptability or versatility
If sheet metal contacts extend into different spatial planes, then connections to various electrical components are facilitated, but manufacturing complexity increases
Solution Approach 1:
The connector is segmented into multiple independent sheet metal contacts, each capable of being formed with specific bends and angles. This segmentation allows each contact to be optimized for reaching specific electrical components while keeping the overall design modular and manageable, reducing the complexity burden compared to a single monolithic structure.
Solution Approach 2:
The sheet metal contacts utilize variations in geometric parameters such as bend angles, contact region positions, and extension lengths to achieve different spatial configurations. By changing these geometric parameters rather than creating entirely different structural designs, the connector can adapt to various connection requirements while maintaining a consistent base design approach.
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 connector assembly enables efficient and flexible connection of batteries to multiple electrical components within devices, supporting increased power demands while maintaining a compact and sealed design, reducing impedance and ensuring reliable electrical connections.
Implementation Method 1
The second sheet metal piece is welded to the second end of the first sheet metal piece
Data Source
AI summary
A connector assembly for connecting a battery to different electrical components within an electrical device includes a housing, and a plurality of sheet metal contacts coupled to and extending through the housing. The plurality of sheet metal contacts define a plurality of battery contact regions and a plurality of internal contact regions spaced form the plurality of battery contact regions. The plurality of internal contact regions physically contact the plurality of different electrical components. A first one of the plurality of internal contact regions is offset from a second one of the plurality of internal contact regions in a different spatial plane than a spatial plane of the second one of the plurality of internal contact regions.