Electrical Connector Segmented Contact Design
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Solution Overview
Problem
Existing electrical connectors face a conflict between increasing the number of contacts for high power transmission and avoiding excessive mating force, as reducing contact width and thickness to lower force also decreases transmission capacity, and increasing them for higher power transmission increases force undesirably.
Innovation Solution
An electrical connector design featuring a primary part with a first spring arm and a secondary part with higher conductivity and thickness, both mechanically and electrically connected, where the secondary part forms an additional transmission path with a solder ball for enhanced power delivery and reduced force, using a Z-shaped configuration with overlapping spring arms and soldering sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of contacts is increased to increase power transmission capacity, then the total reaction force during mating increases undesirably
Solution Approach 1:
The contact is divided into a primary contact portion and a secondary contact portion that are spatially separated and can be independently optimized. The primary contact portion maintains adequate dimensions for low reaction force, while the secondary contact portion can be designed with different dimensions to contribute to power transmission capacity without increasing mating force.
2Force
If the width and thickness of each contact are reduced to lower reaction force, then the power transmission capacity decreases
Solution Approach 1:
The contact structure is segmented into primary and secondary portions with different dimensional characteristics. The primary contact portion has reduced width and thickness to lower reaction force during mating, while the secondary contact portion provides additional cross-sectional area for enhanced power transmission capacity.
Solution Approach 2:
The contact structure utilizes three-dimensional spatial arrangement with the primary and secondary contact portions positioned at different locations and orientations. This dimensional approach allows the secondary portion to contribute to power capacity without adding to the mating reaction force in the primary contact direction.
3Power
If the width and thickness of each contact are increased to enhance power transmission, then the mating reaction force increases undesirably
Solution Approach 1:
The contact is segmented into primary and secondary portions where the primary portion maintains smaller dimensions for low reaction force during mating, while the secondary portion is added separately to increase power transmission capacity without affecting the mating force characteristics of the primary contact.
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 design allows for a large number of contacts for high power transmission while minimizing the undesired high reaction force during mating, by distributing the force effectively through the secondary part's higher conductivity and thickness, thereby optimizing both power transmission and mechanical stability.
Implementation Method 1
The first spring arm extend upwardly through the upper surface for mating with the CPU, and a first soldering section around the lower surface
Data Source
AI summary
A connector includes an insulative housing having opposite upper and lower surfaces with a plurality of passageways extending therethrough, and a plurality of contacts retained in the corresponding passageways, respectively. Each contact includes a primary part and a secondary part discrete from each other. The primary part includes a first main body with a first spring arm extend upwardly through the upper surface for mating with the CPU, and a first soldering section around the lower surface. The secondary part includes a second main body with a second spring arm contacting the first main body, and a second soldering section around the lower surface. A solder ball is attached to the first soldering section and/or the second soldering section.