High Density Electrical Connector Spring Arm Design
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Solution Overview
Problem
Existing electrical connectors mounted on printed circuit boards face challenges in achieving high density due to design features that increase contact width to enhance flexibility, which is not beneficial for high-density applications.
Innovation Solution
The electrical connector design includes a spring arm with a first vertical portion, an arc portion, and a second vertical portion on the same line, which enhances flexibility without increasing the contact width, allowing for oblique contact extension from the second vertical portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the spring portion is bent from the retaining portion to enhance flexibility, then the flexibility of the electrical contact is improved, but the width of the contact increases which is not beneficial for high density applications
Solution Approach 1:
The spring arm is designed with a multi-segment structure including a first vertical portion, a bending portion, and a second vertical portion arranged in sequence. This vertical stacking of functional segments allows the spring arm to achieve flexibility through vertical dimension rather than horizontal expansion, thereby maintaining compact width suitable for high-density applications while providing the necessary elastic deformation capability
Solution Approach 2:
The spring arm is divided into multiple functional segments: a first vertical portion connected to the retaining portion, a bending portion for elastic deformation, and a second vertical portion extending upward. This segmentation allows each portion to perform its specific function efficiently while keeping the overall width compact, resolving the contradiction between flexibility and width
2Reliability
If the length of the contact portion is extended to increase flexibility, then the flexibility of the electrical contact is improved, but the width of the contact increases which reduces density
Solution Approach 1:
Instead of extending the contact portion horizontally to increase flexibility, the design utilizes vertical extension with the first vertical portion and second vertical portion arranged in sequence. This dimensional shift allows flexibility to be achieved through vertical length rather than horizontal width, maintaining high density while providing sufficient flexibility for reliable electrical connection
Solution Approach 2:
The spring arm incorporates a bending portion that provides dynamic elastic deformation capability. This allows the contact to adapt to manufacturing tolerances and assembly variations through controlled flexing, achieving the necessary flexibility without requiring excessive length that would reduce connector density
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 achieves enhanced flexibility of electrical contacts while maintaining the same width, thereby supporting high-density connector applications.
Implementation Method 1
The spring arm has a first vertical portion connected with the body plate, an arc portion bending and extending upwardly from the first vertical portion... The spring arm bending and extending upwardly from a side edge of the flat plate... used to enhance flexibility of the electrical contact
Data Source
AI summary
An electrical connector includes an insulative housing and a number of electrical contacts secured to the insulative housing. Each of the contacts includes a flat plate engaging with the insulative housing, a spring arm bending and extending upwardly from a side edge of the flat plate and a solder tail extending downwardly from a lower portion of the flat plate. The spring arm has a first vertical portion connected with the body plate, an arc portion bending and extending upwardly from the first vertical portion, and a contact portion at a free end of the spring arm. Said arc portion and contact portion are located at same side of the first vertical portion.