Electrical Connector With Segmented Biasing Members
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors face issues with spring means being structurally weak, leading to compromised electrical contact, instability in assembly, and difficulty in conductor insertion and removal due to integral spring design and lack of secure fixation within the housing.
Innovation Solution
A connector assembly with separate biasing members and connector elements, each with a side wall and guide end wall, interacting with a conductive wall to ensure balanced and secure electrical coupling, featuring limiting and stopping means to prevent over-insertion and improve assembly stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two spring means are manufactured directly adjacent each other as one integral part, then ease of assembly into the housing is improved, but structural weakness occurs in the rib portion further from the main wall causing inadequate biasing function
Solution Approach 1:
The patent divides the connector assembly into separate components: a housing, a first connector element with a first spring means, and a second connector element with a second spring means. Each connector element is assembled into the housing separately, eliminating the need for a weak rib structure while maintaining ease of assembly. The segmentation allows each spring means to be independently supported by its own connector element rather than relying on a shared weak rib.
2Ease of manufacture
If a single main wall is provided to hold the two spring means, then alignment with openings is facilitated, but the spring means further from the main wall becomes unbalanced and may not engage conductors securely
Solution Approach 1:
The patent separates the two spring means into different connector elements that are independently assembled into the housing. Each connector element with its spring means is positioned and secured independently, ensuring balanced force distribution and secure engagement for each conductor. This eliminates the imbalance caused by having both spring means attached to a single main wall.
3Device complexity
If no means for fixing the metal contact and spring means is provided, then device complexity is reduced, but assembly accuracy decreases causing malfunction during use
Solution Approach 1:
The patent uses separate connector elements that are independently assembled into the housing, with each connector element maintaining the positional relationship between its metal contact and spring means. This segmentation approach provides inherent fixation through the connector element structure itself, ensuring assembly accuracy without requiring additional complex fixation means.
4Ease of manufacture
If spring means are provided side by side as an integral part, then manufacturing is simplified, but conductors may cross into adjacent voids causing difficulty in removal
Solution Approach 1:
The patent separates the spring means into different connector elements that are independently positioned in the housing. This creates clear separation between the operational zones for each conductor, preventing cross-contamination into adjacent voids. The segmented structure maintains manufacturing simplicity while improving conductor removal by establishing distinct operational boundaries for each connector element.
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 stable and secure electrical connections by balancing the force distribution across separate biasing members, preventing structural weakness and ensuring accurate assembly, while allowing for easy conductor insertion and removal without tools.
Implementation Method 1
a first biasing member disposed in the first portion, the first biasing member being adapted to deflect upon a first electrical conductor being inserted into the first portion
Data Source
Figure 1(a)
Figure 1(b)~1(c)
Figure 1(d)~1(f)
AI summary
A connector assembly and an electrical connector for electrically coupling at least two electrical conductors can be provided whereby the connector assembly comprises a support structure wall separating the assembly into a first and a second portion; a conductive wall for providing electrical connectivity between the first and second portions; a first biasing member disposed in the first portion, the first biasing member being adapted to deflect upon a first electrical conductor being inserted into the first portion, the first biasing member being further adapted to bias the first electrical conductor against the conductive wall; and a second biasing member disposed in the second portion, the second biasing member being adapted to deflect upon a second electrical conductor being inserted into the second portion, the second biasing member being further adapted to bias the second electrical conductor against the conductive wall to electrical couple the first and the second electrical conductors.