Connector Projections for Stable Low-Pressure Contact
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connectors face issues with unstable connections due to contamination layers and require high contact force, especially in environments with fibrous dust or particles, and struggle with low contact pressure and high resistance.
Innovation Solution
A connector design featuring an elastic body with conductive layers and projections that can push aside contamination layers, allowing for multipoint contact with low pressure, using an elastic body with grooves and a sheet member with projections to ensure stable connections even in contaminated environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a smooth conductive layer is used for contact, then manufacturing is easier and the structure is simpler, but the contact pressure required is high and connection stability is poor in contaminated environments
Solution Approach 1:
The conductive layer is designed with protrusions having curved surfaces instead of flat surfaces. These curved surfaces concentrate contact force at specific points, enabling the contact to penetrate contamination layers more effectively while maintaining reliable electrical connection at lower overall contact pressures.
Solution Approach 2:
The conductive layer transitions from a uniformly smooth surface to a structure with localized protrusions. These protrusions create localized high-contact-force points that can penetrate contamination, while the overall contact pressure remains low. Each protrusion acts as a localized contact point with enhanced penetrating capability.
2Reliability
If multiple plating layers are applied to reduce connection resistance, then electrical performance improves, but the contact portion cannot follow the surface profile and requires large deformation force
Solution Approach 1:
The protrusions on the conductive layer have curved surfaces that can elastically deform to conform to the surface profile of the contact object. This curvature allows the multi-layer plated structure to follow the surface contours without requiring excessive deformation force, while still achieving sufficient contact pressure at the protrusion tips for low connection resistance.
Solution Approach 2:
The conductive layer with protrusions exhibits dynamic deformation characteristics, allowing the protrusions to elastically deform and adapt to the contact object's surface profile during connection. This dynamic adjustment enables the rigid multi-layer plated structure to conform to surface variations while maintaining electrical contact.
3Volume of moving object
If the pitch of contacts is narrowed to reduce connector size, then miniaturization is achieved, but the connector becomes more sensitive to contamination and misalignment
Solution Approach 1:
The protrusions with curved surfaces can penetrate contamination layers more effectively, which is particularly important for narrow-pitch connectors that are more susceptible to contamination issues. The curved contact surfaces provide a mechanical advantage in pushing through contaminants to establish reliable electrical contact even at reduced pitches.
Solution Approach 2:
By concentrating contact function into localized protrusions rather than distributed smooth surfaces, the design enhances the effectiveness of each individual contact point. This is especially beneficial for narrow-pitch applications where each contact point must be highly reliable to compensate for the reduced margin for error in alignment and contamination resistance.
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 achieves stable and reliable electrical connections with low contact pressure, maintaining resistance consistency even with contamination, and is suitable for high-density contact applications.
Implementation Method 1
a body portion comprising an elastic body and a conductive layer extending along a surface of the body portion
Implementation Method 2
the conductive layer has a plurality of projections projecting outward
Data Source
AI summary
For achieving electrical connection by contact with a connection object, a connector includes a body portion including an elastic body. A conductive layer extends along a surface of the body portion and is adapted for contact with the connection object. The conductive layer has a plurality of projections projecting outward.