Electrical Connector Z-Shape Contact for Low Profile High Current
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrical connectors are unable to meet the requirements of low-profile and high-current, limiting the design flexibility of electronic products due to their height and posing challenges in utilizing the limited internal space for contact positioning.
Innovation Solution
An electrical connector design featuring an insulative housing with a main body, mating ports, and contacts that include a Z-shape intermediate portion with widened sections for secure engagement within the housing, allowing for low-profile and high-current capabilities while providing stable retention and efficient space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional electrical connector structures are used, then the connector can maintain structural simplicity, but the height of the connector increases, limiting the inner space of electronic products
Solution Approach 1:
The contact structure is nested within the insulative housing, with the intermediate portion received in receiving passages and channels defined by the housing. The widened sections of the contact are received in corresponding widened sections of the housing, creating a nested arrangement that reduces overall height while maintaining structural integrity.
Solution Approach 2:
The contact structure transitions from a conventional linear arrangement to a three-dimensional Z-shape configuration with intermediate portion having first and second horizontal sections at different heights connected by a vertical section. This dimensional change allows the contact to fit within the limited height space of the low-profile connector.
2Length of moving object
If the height of electrical connector is reduced, then the inner space of electronic product is increased, but the retention of contacts within the housing becomes less reliable
Solution Approach 1:
The contact structure features localized widened sections at specific positions (first widened section and second widened section) that provide enhanced engagement with corresponding widened sections in the housing. This local quality enhancement ensures reliable retention at critical points while maintaining overall compact dimensions.
Solution Approach 2:
The intermediate portion of the contact is configured with curved surfaces that match the curved surfaces of the receiving passages and channels in the housing. This curvature compatibility ensures smooth insertion and reliable retention, with the rounded geometry distributing contact stresses more evenly.
3Volume of moving object
If conventional contact positioning is used, then the manufacturing process is simple, but the utilization of limited internal space for contact positioning is insufficient
Solution Approach 1:
The contact structure is segmented into distinct portions: mating portion, intermediate portion with horizontal sections and vertical connection, and termination portion. The intermediate portion is further divided into first and second horizontal sections with widened areas. This segmentation allows each section to be optimized for its specific function while maintaining manufacturability through standard forming processes.
Data Source
AI summary
An electrical connector includes an insulative housing and at least one first contact received in the insulative housing. The insulative housing includes a main body and a first mating port extending from the main body. The at least one first contact includes a first mating portion partially exposed into the first mating port, a first intermediate portion extending rearward from the first mating portion and received in the main body, and a first termination portion bending downward from the first intermediate portion and exposed beyond the insulative housing. The first intermediate portion includes a first lower horizontal section, a first upper horizontal section parallel to the first lower horizontal section, and a first connecting portion connecting the first lower horizontal section and the first upper horizontal section. The first lower horizontal section is formed with a first lower widened section, and the first upper horizontal section is formed with a first upper widened section.