Electrical Connector Miniaturization via Inverted Elastic Contacts
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Solution Overview
Problem
Existing electrical connectors face challenges in achieving stable connections with sufficient strength while minimizing size and overall height, as thin walls for miniaturization compromise strength, and previous solutions like point contacts and curved elastic portions impede miniaturization efforts.
Innovation Solution
The electrical connector design features L-shaped plug contacts with recesses for stable contact and chamfered receptacle contacts, along with flat shape fixtures and a housing configuration that ensures secure engagement and positioning, maintaining strength and stability while allowing for miniaturization and reduced height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If walls of the connector are made thin to achieve miniaturization and reduced overall height, then the size and height are reduced, but the strength of the connector is lowered
Solution Approach 1:
The patent applies local quality by making the walls thin in most areas for miniaturization, but locally thickening specific wall portions (first and second wall portions) at critical locations where strength is needed for stable connection. This allows the connector to be miniaturized overall while maintaining sufficient strength at key engagement points.
2Reliability
If curved elastic portions are added to receptacle contacts to improve connection stability, then connection stability is enhanced, but miniaturization in width directions is impeded
Solution Approach 1:
Instead of making the receptacle contacts curved and elastic (the conventional approach), the patent inverts the approach by making the plug contacts curved and elastic. This allows the elastic deformation to occur in the plug connector rather than the receptacle connector, achieving connection stability without increasing the width dimension of the receptacle connector.
Solution Approach 2:
The patent moves the elastic portion from the receptacle contact to the plug contact, utilizing the longitudinal dimension of the plug connector to accommodate the curved elastic portion. This dimensional relocation allows connection stability to be achieved without compromising the width miniaturization of the overall connector assembly.
3Reliability
If fixtures are added to longitudinal ends for stable engagement, then connection stability is improved, but miniaturization in longitudinal directions is impeded
Solution Approach 1:
The patent merges the engagement function with the contact portions themselves. The plug contacts and receptacle contacts are designed to engage directly with each other through their contact portions, eliminating the need for separate fixtures at the longitudinal ends. This integration achieves stable engagement while maintaining miniaturization in the longitudinal direction.
4Reliability
If contact portions of receptacle contacts stand upright for sufficient displacement, then connection stability is improved, but thick central portion is required which impedes miniaturization in width directions
Solution Approach 1:
The patent inverts the conventional design by making the plug contacts (rather than receptacle contacts) have the curved elastic portions that provide displacement. The plug contacts are designed to deform elastically during engagement, providing the necessary displacement for stable connection without requiring the receptacle contacts to stand upright with thick central portions.
Data Source
AI summary
Upon plug and receptacle connectors of an electrical connector being fitted with each other, positioning recesses of a block of the plug connector engage positioning protrusions of a housing of the receptacle connector to achieve positioning of the two connectors in their width directions. Inclined portions of receptacle contacts of the receptacle connector are commensurate with inclined portions of inserting holes of the housing so that a backup function of the housing for the receptacle contacts is adjusted to obtain a stable connection between the plug and receptacle connectors. First chamfered portions of the receptacle contacts engage recesses of the plug contacts to generate tactile clicks and to achieve the positioning and contacting between the plug and receptacle contacts. The plug contacts are embraced between contact portions and elastic portions of the receptacle contacts to obtain a stable connection between the both contacts.