Four-way Raceway Connector with Segmented Cross Contacts
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Solution Overview
Problem
Conventional electrical connector configurations often experience incomplete engagement due to foreign matter on the surface of tab contacts, requiring higher insertion force and compromising reliability, especially when using multiple contact points.
Innovation Solution
A raceway connector with a multiple-tiered configuration featuring four-way terminal sets, each with first, second, third, and fourth terminals, arranged in a specific angular orientation and housed within individual connectors, providing multiple contact locations to ensure secure and reliable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple contact points are used to improve reliability, then connection reliability should improve, but foreign matter on contact surfaces causes incomplete engagement and requires higher insertion force
Solution Approach 1:
The connector is divided into four separate contact points arranged in a cross pattern, with each contact point independently engaging the tab contact from a different direction. This segmentation allows the force to be distributed across multiple points rather than concentrated at a single location, reducing the overall insertion force required while maintaining reliable connection.
Solution Approach 2:
The contact points are arranged in a two-dimensional cross pattern rather than a linear arrangement, with contacts positioned at 90-degree angles to each other. This dimensional arrangement allows simultaneous engagement from multiple directions, improving reliability while distributing the insertion force across different spatial locations.
2Force
If conventional single-point contact is used, then insertion force is lower, but connection reliability is compromised due to foreign matter and incomplete engagement
Solution Approach 1:
The single contact point is segmented into four separate contact points arranged in a cross pattern. Each contact point independently engages the tab contact, providing multiple pathways for electrical connection. This segmentation ensures that foreign matter at one contact point does not prevent engagement at other points, maintaining reliability.
Solution Approach 2:
Each contact point is designed with specific local characteristics, including resilient arms that can independently deflect and engage the tab contact. The contact points have different spatial orientations and engagement directions, allowing each to compensate for issues at other contact points and ensuring overall connection reliability.
3Reliability
If four-way terminal sets with multiple contact points are implemented, then connection reliability improves, but device complexity increases
Solution Approach 1:
Four separate contact points are merged into a single integrated connector body, with all contacts sharing common mounting structures and support elements. The resilient arms and contact points are arranged in a compact cross pattern that minimizes overall connector size and simplifies installation while maintaining the reliability benefits of multiple contact points.
Solution Approach 2:
The connector design uses standardized terminal configurations and resilient arm structures that can be applied across different connector types and applications. The four-way cross contact arrangement serves multiple functions: providing redundant electrical paths, distributing mechanical stress, and ensuring engagement from multiple directions, thereby improving reliability without proportionally increasing complexity.
Data Source
AI summary
A raceway connector (300) includes a first vertical terminal set (302) and a second vertical terminal set (310). Each vertical terminal set (302, 310) includes double end terminals (304) with first and second female connectors (306, 308). The vertical terminal sets (302, 310) are held in position by a left-outside housing (314), a center connector (328) and a right-side housing (324). The raceway connector (300) is adapted to be interconnected to four junction blocks (344).