Floating Contact Terminal for Compact Connectors
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Solution Overview
Problem
Conventional electrical connector systems face challenges in reducing size while maintaining mechanical and electrical reliability, as smaller pitch interconnects are prone to reliability issues and are costly to manufacture, with limited customization options to meet specific user needs.
Innovation Solution
The electrical connector system features a base portion with an insulation displacement connecting portion and a contact portion that includes a pair of arms configured to deflect when making contact, allowing for a reduced overall connector size with increased spring beam length and spring force, enabling blind mating and reduced localized stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If contact pitch is reduced to decrease interconnect size, then the number of electrical connections per unit space increases, but mechanical and electrical reliability deteriorates
Solution Approach 1:
The contact portion is designed as a floating, resilient structure with spring beams that can deflect and adapt dynamically during mating. This dynamic capability allows the contact to maintain reliable electrical connection even at reduced pitch by accommodating manufacturing tolerances and assembly variations through elastic deformation, thereby improving reliability while maintaining small size.
Solution Approach 2:
The invention changes the structural parameters of the contact portion by introducing a floating design with specific spring beam dimensions and material properties. This allows the contact to exhibit controlled elasticity and deflection characteristics that ensure reliable mating at reduced pitch, overcoming the reliability issues associated with smaller connector sizes.
2Area of stationary object
If contact pitch is reduced to decrease interconnect size, then space efficiency improves, but manufacturing cost increases
Solution Approach 1:
The contact terminal is segmented into distinct functional portions: base portion, insulation displacement connecting portion, and contact portion. This segmentation allows each part to be optimized independently for manufacturing, with the contact portion using cost-effective resilient beam structures that can be mass-produced through stamping or molding techniques, reducing overall manufacturing cost despite reduced pitch.
Solution Approach 2:
The contact portion serves multiple functions simultaneously: it provides electrical connection, mechanical resilience, and self-alignment capabilities through its floating design. This multi-functionality reduces the need for additional components or complex assembly steps, thereby lowering manufacturing costs while maintaining small connector size.
3Area of stationary object
If contact pitch is reduced to decrease interconnect size, then space efficiency improves, but device complexity increases
Solution Approach 1:
The invention merges multiple functions into the contact portion: the floating resilient structure combines electrical contact, mechanical compliance, and self-alignment features that would traditionally require separate components. This integration simplifies the overall connector structure while maintaining reduced pitch, thereby decreasing device complexity despite the space constraints.
4Reliability
If spring beam length is increased to improve reliability, then connector size increases, but contact force and electrical reliability improve
Solution Approach 1:
The spring beams are oriented in the vertical dimension (extending upwardly from the base portion) rather than horizontally, allowing increased spring beam length to be achieved without increasing the horizontal connector footprint. This dimensional arrangement enables improved contact force and electrical reliability while maintaining compact connector size in the critical horizontal plane.
Solution Approach 2:
The resilient properties are localized to the contact portion with specifically designed spring beams, while the base portion and insulation displacement portion maintain rigid structures. This localized elasticity provides the necessary compliance for reliable contact without requiring the entire connector to be larger, thereby improving reliability without increasing overall connector size.
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 results in a smaller, more reliable, and cost-effective electrical connector system that can accommodate various pitch sizes, including 2.0 mm, 0.050″, 1.0 mm, 0.8 mm, and 0.5 mm, with improved mechanical and electrical performance.
Implementation Method 1
The second arm is configured to deflect when making electrical contact with a mating contact pin
Data Source
AI summary
An electrical contact terminal includes a base portion for positioning and retaining the electrical contact terminal within a connector housing, an insulation displacement connecting portion extending upwardly from the base portion and comprising a pair of spaced apart arms defining an opening therebetween for receiving and making electrical contact with an electrical conductor, and a contact portion extending downwardly from the base portion and configured to float when the electrical contact terminal is retained and positioned within a connector housing. The contact portion includes a first arm, a second arm, and an arcuate base portion. The first arm extends downwardly and includes a first end attached to the base portion and an opposite second end. The second arm extends downwardly and includes a free first end closer to the base portion and an opposite second end farther from the base portion. The second arm is configured to deflect when making electrical contact with a mating contact pin. The arcuate base portion connects the second ends of the first and second arms.