Connector Terminal Sleeve for Air Gap Tolerance Control
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Solution Overview
Problem
In connector systems, the presence of air gaps between mated terminal assemblies due to varying tolerances makes it difficult to achieve the small tolerance allowance required for high performance and reduced size, especially when trying to transmit higher data speeds.
Innovation Solution
A terminal system design that includes a movable sleeve around the first terminal assembly, which adjusts from an insertion position to an end position along a longitudinal direction while the first terminal assembly remains stationary, allowing for precise alignment and minimization of the air gap between mated terminal assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple tolerance ranges are present in the connector system for various parts, then manufacturing flexibility is improved, but the air gap size becomes difficult to control within the required small tolerance allowance
Solution Approach 1:
The patent introduces a movable sleeve as an intermediary component between the terminal assembly and the outer housing. This sleeve absorbs and compensates for the cumulative tolerances of multiple parts, preventing them from directly affecting the air gap size at the connector interface. The sleeve acts as a mediator that decouples the manufacturing tolerances from the critical air gap dimension.
Solution Approach 2:
The patent employs a movable sleeve that can dynamically adjust its position along the longitudinal direction of the connector. This dynamic adjustment capability allows the sleeve to compensate for tolerance variations and maintain the air gap within the required tolerance allowance, transforming a static tolerance accumulation problem into a dynamically adjustable solution.
2Reliability
If the terminal system is designed for high data speed transmission and minimized size, then performance is improved, but the tolerance allowance for air gap size becomes smaller and harder to meet
Solution Approach 1:
The movable sleeve serves as a mediator that isolates the critical air gap dimension from the cumulative effects of multiple component tolerances. By introducing this intermediate component, the system can achieve the tight air gap tolerances required for high performance without proportionally increasing the manufacturing precision requirements for all individual parts.
Solution Approach 2:
The dynamic adjustability of the sleeve allows the system to meet stringent air gap tolerance requirements for high-performance applications. The sleeve can be positioned to compensate for tolerance variations, ensuring that the air gap remains within the small tolerance allowance needed for high data speed transmission, even when individual component tolerances are not extremely tight.
3Manufacturing precision
If the terminal assembly position is adjusted to minimize air gap, then connector interface precision is improved, but the complexity of maintaining position while accommodating other tolerances increases
Solution Approach 1:
The patent segments the connector system into distinct functional components: the terminal assembly, the movable sleeve, and the outer housing. This segmentation allows the position of the terminal assembly to be optimized for minimal air gap while the sleeve independently handles the accommodation of other tolerances. The segmentation decouples the position maintenance function from the tolerance accommodation function, reducing overall system complexity.
Solution Approach 2:
The movable sleeve provides a dynamic mechanism for maintaining the terminal assembly position while accommodating other tolerances. Rather than requiring a complex rigid structure to maintain position, the dynamic sleeve can adjust its position to absorb tolerance variations, simplifying the overall design while maintaining precision at the connector interface.
Data Source
AI summary
A terminal system includes a first terminal assembly, a sleeve disposed around the first terminal assembly, and a second terminal assembly matable with the first terminal assembly along a longitudinal direction. The sleeve is movable with respect to the first terminal assembly from an insertion position to an end position along the longitudinal direction toward the second terminal assembly while the first terminal assembly remains stationary in a mated position with the second terminal assembly.