Deflectable Pin Contacts for Electrical Connectors
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Solution Overview
Problem
Electrical connectors in high-speed communication systems, such as backplane or midplane systems, experience high mating forces during engagement and disengagement, which can be cumulative and potentially damaging.
Innovation Solution
The design incorporates pin contacts with first and second deflectable beams at the mating end, which engage flexible contact fingers of a mating connector, deflecting inward and outward to reduce the mating forces by allowing the flexible contact fingers to deflect and pinch the header contacts, thereby reducing the force required for mating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If traditional rigid electrical contacts are used, then structural simplicity is maintained, but mating forces become excessively high and cumulative
Solution Approach 1:
The electrical contact is segmented into multiple functional regions: a body portion and two deflectable beams extending from opposite sides. This segmentation allows each beam to independently deflect during mating, distributing the mating force across multiple flexible elements rather than a single rigid structure, thereby reducing overall mating force while maintaining structural integrity.
Solution Approach 2:
The contact structure transitions from a static rigid form to a dynamic flexible structure. The deflectable beams are designed to bend and adapt their shape during the mating operation, allowing the contact to absorb mating forces through elastic deformation. This dynamic behavior reduces peak mating forces compared to rigid contacts that would transmit all forces directly.
2Ease of operation
If rigid contacts are used, then manufacturing simplicity is maintained, but ease of operation deteriorates due to high mating forces
Solution Approach 1:
The contact structure utilizes changes in physical parameters, specifically the flexibility parameter of the beams. By designing beams with appropriate thickness, length, and material properties, the contact achieves optimal flexibility to reduce mating forces. The beams are engineered to have controlled deflection characteristics that ease the mating operation while maintaining manufacturability through standard fabrication processes.
3Reliability
If flexible contact fingers are used in the mating connector, then mating forces are reduced, but contact structure complexity increases
Solution Approach 1:
The deflectable beams are designed to be self-compliant, automatically adjusting their deflection to match the flexibility of the mating connector's contact fingers. This self-service mechanism eliminates the need for complex control systems or adjustment mechanisms, as the flexible beams naturally adapt to ensure reliable electrical connection while reducing mating forces through their inherent compliance.
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 effectively lowers the mating forces between electrical connectors, making the mating operation easier and potentially reducing wear and tear on the connectors, while maintaining reliable electrical connections.
Implementation Method 1
Each of the pin contacts has first and second deflectable beams at the mating end. The first deflectable beam are configured to engage a first flexible contact finger of the mating connector and deflect toward the central plane during the mating operation. The second deflectable beam is configured to engage a second flexible contact finger of the mating connector and deflect toward the central plane during the mating operation.
Data Source
AI summary
An electrical connector includes a connector housing configured to engage a mating connector during a mating operation. A contact array includes pin contacts coupled to the connector housing. Each of the pin contacts have an elongated body including a central plane that extends along a longitudinal axis to a mating end. Each of the pin contacts has first and second deflectable beams at the mating end. The first deflectable beam are configured to engage a first flexible contact finger of the mating connector and deflect toward the central plane during the mating operation. The second deflectable beam is configured to engage a second flexible contact finger of the mating connector and deflect toward the central plane during the mating operation.