Flexible Connector Assembly With Spherical Contacts
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Solution Overview
Problem
Conventional implantable wiring harnesses face challenges in reliability, biocompatibility, ease of installation, and patient comfort due to their rigidity and inability to handle multiple power and control channels effectively, especially in environments with varying forces and environmental stresses.
Innovation Solution
A flexible connector assembly comprising a plug and receptacle connector with spherical electrical contacts and elastomeric materials, designed to minimize volume, reduce voltage drops, and provide sealed, isolated connections for power and sensor cables, allowing for flexibility and strain relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rigid connector approaches are used, then electrical connection reliability is improved, but flexibility and patient comfort deteriorate
Solution Approach 1:
The connector assembly uses an elastomeric plug connector that can be flexed and deformed, replacing rigid connector structures. This flexible elastomeric material maintains electrical connection reliability while providing the necessary flexibility for implantation and patient comfort.
Solution Approach 2:
The invention combines elastomeric materials with metallic electrical contacts to create a composite connector assembly. The elastomeric portion provides flexibility and biocompatibility, while the metallic contacts ensure reliable electrical connection, resolving the contradiction between rigidity and flexibility.
2Reliability
If spherical electrical contacts are used, then voltage drops between contacts are reduced, but manufacturing complexity increases
Solution Approach 1:
The electrical contacts are formed with spherical surface portions that create a spherical interface upon make-up. This spherical geometry reduces voltage drops between contacts by improving contact area and distribution, while the elastomeric material allows for relatively simple molding of these spherical features.
3Volume of moving object
If multiple electrical contacts are integrated in a small volume, then device size is reduced, but electrical isolation between contacts becomes difficult
Solution Approach 1:
The elastomeric plug connector acts as an insulating barrier between multiple electrical contacts, providing electrical isolation while maintaining a compact volume. The flexible elastomeric material can be molded to provide precise isolation features between adjacent contacts.
Solution Approach 2:
The connector design provides localized electrical isolation between adjacent contacts through the elastomeric material and sealing features positioned specifically between contacts. This allows multiple contacts to be integrated in a small volume while maintaining reliable electrical isolation where needed.
4Ease of operation
If helically coiled cables are used, then flexibility and strain relief are improved, but device volume increases
Solution Approach 1:
The cables are configured in a helically coiled arrangement that provides dynamic flexibility and strain relief. The helical configuration allows the cables to expand and contract, absorb movement, and relieve strain while maintaining a relatively compact volume compared to rigid cable arrangements.
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
The solution provides a reliable, biocompatible, and minimally invasive connector system that maximizes patient comfort by reducing voltage drops and preventing shorting or corrosion, while allowing for easy installation and flexibility to accommodate multiple channels.
Implementation Method 1
The electrical contacts of the plug connector and the receptacle connector have spherical surface portions whereby a spherical interface between the electrical contacts is formed upon make-up and reduces voltage drops between the contacts
Implementation Method 2
Upon insertion of the elongated connector body into the cavity, the peripheral surface of the elongated connector body located between adjacent first contacts sealingly engages the wall to electrically isolate adjacent first contacts from each other
Data Source
AI summary
The present invention is directed to a linear connector assembly comprising a plug connector (22) and a receptacle connector (24). The plug connector (22) includes an elongated member (26), and an electrical contact (72) disposed about a portion of the elongated member. The receptacle connector (24) includes a wall defining a cavity (44) dimensioned to sealingly receive the elongated member, and an electrical contact having a surface disposed in the wall for electrical connection with the plug contact. The electrical contacts of the plug connector (22) and the receptacle connector (24) have spherical surface portions whereby a spherical interlace between the electrical contacts is formed upon make-up and reduces voltage drops between the contacts.