High Contact Density Electrical Connector With Segmented Lead Insertion Chamber
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Solution Overview
Problem
Existing electrical connectors face challenges in achieving high contact density and efficient assembly for connecting multiple leads to double-sided printed circuit boards, particularly in miniaturized electronics where space and weight constraints are stringent.
Innovation Solution
The electrical connector features a housing with a receiving slot for a double-sided PCB, equipped with two electrically insulated contact springs on opposite sides, each forming a lead contact in a split lead insertion chamber, allowing for dual connections per position and enhanced assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a single contact spring is used per position, then the device complexity is low, but the contact density is insufficient
Solution Approach 1:
The lead insertion chamber is segmented into two separate compartments by a separation wall, allowing two contact springs to be mounted in different compartments. This segmentation enables dual connections per position while maintaining organizational clarity and reducing accidental connections between leads.
Solution Approach 2:
The connector utilizes the vertical dimension by arranging contact springs on opposite sides of the receiving slot, effectively doubling the contact density without increasing the horizontal footprint. This dimensional approach allows high-density connectivity within compact space constraints.
2Quantity of substance
If multiple leads are connected per position, then the connection density increases, but the risk of accidental connections increases
Solution Approach 1:
The lead insertion chamber is divided into two separate compartments by a separation wall, physically isolating the two contact springs and their associated leads. This segmentation prevents accidental connections by ensuring that each lead is inserted into its designated compartment, reducing the risk of misconnection.
Solution Approach 2:
The separation wall acts as an intermediary barrier between the two contact springs and lead insertion paths. This intermediate structure provides mechanical isolation and guidance, ensuring that leads are directed to the correct compartment and preventing cross-contamination or accidental contact between adjacent leads.
3Strength
If traditional hot-welding methods are used, then the connection strength is high, but thermal stress is generated
Solution Approach 1:
The patent replaces thermal welding processes with cold-welding technology, where contact springs with low-strength metal tips (such as copper or aluminum) are pressed against lead contacts under controlled pressure. This mechanical bonding method eliminates thermal stress and flux requirements while producing smooth joints without thermal damage to surrounding components.
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
This design doubles the connection density and improves assembly efficiency by allowing two electrical circuits to be terminated on a double-sided PCB while preventing accidental connections and reducing thermal stress through cold-welded contacts.
Implementation Method 1
two contact springs (12) which are arranged on opposite sides of the receiving slot (4) and are electrically insulated from one another
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to an electrical connector (1) for connecting at least two leads (18) to a double-sided printed circuit board (6). The electrical connector (1) comprises a housing (2) with a receiving slot (4) being configured for insertion of the double-sided printed circuit board (6), and at least two contact springs (12), which are arranged on opposite sides of the receiving slot (4), the two contact springs (12) being electrically insulated from one another. In order to increase the contact density of the electrical connector, the housing (2) further comprises at least one lead insertion chamber (20), and the at least two contact springs (12) extend into the at least one lead insertion chamber (20), each contact spring (12) forming a lead contact (16) for a different lead (18).