Floating Connector Contact Head for Alignment-Tolerant Mating
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Solution Overview
Problem
Existing floating connectors with surface-to-surface contact require precise alignment and positioning, leading to low efficiency and high requirements for matching, which limits their tolerance and reliability in connecting external plug connectors.
Innovation Solution
The electrical connecting member features a contact head portion with an extending segment and a bending segment, forming an arc-shaped protrusion that is elastically guided to an electrical contact region, allowing for adaptive and efficient electrical contact with external components, even with deviations in alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If surface-to-surface contact is used in floating connectors, then alignment tolerance is reduced and matching precision is improved, but connection efficiency decreases and operational requirements become more stringent
Solution Approach 1:
The contact head portion is segmented into an extending segment and a bending segment, allowing independent deformation of each segment. This segmentation enables the contact structure to adapt to alignment deviations while maintaining reliable electrical contact, thus improving connection efficiency without sacrificing alignment precision requirements
Solution Approach 2:
The bending segment is designed to be elastically deformable, transitioning from a static rigid contact structure to a dynamic adaptive one. This dynamic characteristic allows the contact head to automatically adjust its position and orientation during connection, accommodating alignment tolerances and reducing matching precision requirements while maintaining connection efficiency
2Reliability
If higher insertion precision is required to ensure reliable contact fit, then contact effectiveness is improved, but manufacturing complexity and operational difficulty increase
Solution Approach 1:
The bending segment serves itself by automatically deforming to compensate for alignment deviations during the connection process. This self-adjusting mechanism eliminates the need for complex external positioning systems or precision adjustment mechanisms, maintaining contact reliability while reducing structural complexity
Solution Approach 2:
The elastic properties and geometric parameters of the bending segment are optimized to provide the necessary compliance for reliable contact. By carefully controlling the thickness, length, and material properties of the bending segment, the design achieves reliable contact fit without requiring higher insertion precision or increasing structural complexity
3Strength
If the contact structure is made rigid to maintain structural strength, then durability is improved, but adaptability to alignment deviations decreases
Solution Approach 1:
Different segments of the contact head have different mechanical properties: the extending segment provides structural strength and positioning, while the bending segment provides flexibility and adaptability. This local differentiation of mechanical properties allows the overall structure to maintain strength while achieving adaptability to alignment deviations
Solution Approach 2:
The contact head portion combines rigid and flexible characteristics within a single integrated structure. The extending segment and bending segment work together as a composite system, where the rigid extending segment provides structural support and the flexible bending segment provides adaptation, achieving both strength and adaptability simultaneously
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 enhances the operability and reliability of the elastic contact, improves the contact mode, and extends the service life of the electrical connecting member by allowing for flexible engagement with external contact components and reducing the risk of collapse due to frequent use.
Implementation Method 1
The floating inner shell is configured to be movable relative to the outer shell through elastic deformation of the elastic contact
Implementation Method 2
The bending segment is bent towards a lower part of the electrical contact region, and the bending segment is connected to the second fixing portion through the extending segment. A free end of the bending segment is bent towards the extending segment to form an arc-shaped protrusion
Data Source
AI summary
An electrical connecting member includes an elastic connecting portion, a first fixing portion, and a second fixing portion. The first fixing portion and the second fixing portion are respectively disposed on two sides of the elastic connecting portion. A contact head portion is disposed on the second fixing portion in an upward direction. The contact head portion includes an extending segment and a bending segment. An electrical contact region is defined between the extending segment and the connecting portion. The bending segment is bent towards a lower portion of the electrical contact region and is connected to the second fixing portion through the extending segment. A free end of the bending segment is bent towards the extending segment to form an arc-shaped protrusion and is disposed in the accommodating groove.