Floating Electrical Connector Assembly for Tolerance and Vibration
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Solution Overview
Problem
Existing electrical connectors face challenges with axial or radial misalignment due to assembling tolerance, leading to poor contact reliability and signal transmission issues, especially under vibrating conditions such as in vehicles.
Innovation Solution
The electrical connector design includes an insulative fixing seat, an insulative floating seat, and a floating terminal with a float connecting portion that allows for flexible deformation in three-dimensional space, along with an elastic conductive shell that constrains the floating seat to maintain alignment and contact under vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a floating-type male connector is used to adapt to assembling tolerance, then the connector can accommodate misalignment between male and female connectors, but the connector has limited floating range and poor flexibility under vibrating conditions
Solution Approach 1:
The patent applies the dynamics principle by designing a floating terminal with an elastic connecting portion that can dynamically adjust its position. The float connecting portion includes bending portions that enable the terminal to flex and adapt to misalignment in multiple directions, transforming a static connector into a dynamic one that can respond to assembly variations and vibration conditions.
Solution Approach 2:
The patent employs parameter changes by modifying the physical state of the float connecting portion through elastic deformation. The bending portions of the float connecting portion can change their curvature and orientation to accommodate misalignment, effectively changing the geometric parameters of the connector to maintain contact under varying conditions.
2Adaptability or versatility
If the float connecting portion is designed with multiple bending portions for flexibility, then the terminal can adapt to misalignment in multiple directions, but the structure becomes more complex
Solution Approach 1:
The patent applies segmentation by dividing the float connecting portion into multiple bending portions (first, second, and third bending portions) that can independently deform. This segmentation allows each portion to handle misalignment in specific directions, providing comprehensive adaptability while maintaining a modular structure that is easier to manufacture and analyze.
3Manufacturing precision
If the insulative floating seat is designed to float above the insulative fixing seat, then the connector can accommodate axial and radial misalignment, but the connector may become misaligned due to vibration
Solution Approach 1:
The patent applies beforehand cushioning by designing the float connecting portion with elastic bending portions that can absorb and cushion the effects of vibration before they cause misalignment. The elastic structure acts as a shock-absorbing mechanism that maintains contact stability under vibrating conditions, preventing harmful effects from propagating through the connector.
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 ensures reliable mating and stable signal transmission even under vibrating conditions by accommodating misalignment and maintaining contact between the floating terminal and the male connector, enhancing the connector's adaptability to assembling tolerance and operational stability.
Implementation Method 1
a float connecting portion which is elastically connected between the mating portion and the horizontal fixing portion and formed by bending multiple times
Implementation Method 2
a conductive shell which sheathes an outer side of the insulative fixing seat, the conductive shell has a plurality of elastic mating pieces which extend upwardly
Data Source
AI summary
An electrical connector and an electrical connector assembly include an insulative fixing seat, an insulative floating seat, a floating terminal and a conductive shell, the insulative fixing seat has a terminal receiving groove, a bottom portion of the terminal receiving groove has a terminal fixing groove which extends horizontally, the insulative floating seat is floatingly mounted above the insulative fixing seat, the insulative floating seat has an insertion hole which penetrates up and down, an outer wall of the insulative floating seat is provided with an annular groove, the floating terminal is fixed in the insulative fixing seat, the floating terminal includes a soldering tail portion, a horizontal fixing portion which is connected with the soldering tail portion, a mating portion and a float connecting portion which is elastically connected between the mating portion and the horizontal fixing portion, the float connecting portion is capable of being floatingly received in the terminal receiving groove, the mating portion extends into the insertion hole of the insulative floating seat, the conductive shell sheathes the insulative fixing seat, the conductive shell has a plurality of elastic mating pieces which extend upwardly, a tip of the elastic mating piece extends into the annular groove. The electrical connector may be better adapted to assembling tolerance and maintain normal operation under a vibrating circumstance.