Ground Contact Beam Structure for Tolerance-Tolerant Connectors
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Solution Overview
Problem
Existing connector technologies face challenges in maintaining stable contact between electrical conductors with protrusions and contacts due to increased structural complexity and finer contact pitches, making it difficult to manage dimensional and shape tolerances effectively.
Innovation Solution
A ground contact connecting member with a support portion and contacting beams is introduced, allowing for flexible alignment and contact with ground contacts, ensuring equipotentiality and stable connection despite misalignment and tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electrical conductor with protrusions is used to make contacts equipotential, then the ground contacts become equipotential, but it becomes difficult to maintain stable contact due to increased structural complexity and finer contact pitches
Solution Approach 1:
The electrical conductor is divided into multiple protrusions that can independently contact different ground contacts. Each protrusion acts as a separate element that can accommodate dimensional variations and tolerance deviations, ensuring reliable equipotential connection even when manufacturing precision varies
Solution Approach 2:
The design allows for parameter variations in the protrusions (such as position, shape, and size) to accommodate tolerance deviations. By enabling parameter changes within acceptable ranges, the system maintains stable contact without requiring extremely tight manufacturing tolerances
2Reliability
If strict management of dimensional and shape tolerances is implemented, then stable contact between protrusions and contacts is achieved, but device complexity and difficulty of assembly increase
Solution Approach 1:
The connector design incorporates floating ranges that allow dynamic adjustment of the electrical conductor's position relative to the contacts. This dynamic capability enables the system to accommodate misalignment without requiring strict tolerance management, simplifying the overall device complexity
Solution Approach 2:
The electrical conductor is designed to perform multiple functions: making ground contacts equipotential, accommodating tolerance deviations, and adapting to misalignment. This multi-functionality reduces the need for additional components and simplifies tolerance management
3Reliability
If the electrical conductor is made rigid to ensure stable contact, then contact stability improves, but adaptability to misalignment and floating ranges decreases
Solution Approach 1:
The electrical conductor incorporates flexible elements such as elastic protrusions that can deform to accommodate misalignment and floating ranges. This flexibility allows the conductor to adapt to positional variations while maintaining stable electrical contact
Solution Approach 2:
The design allows the electrical conductor to dynamically adjust its position and shape within floating ranges. This dynamic adaptability enables the system to handle misalignment while maintaining reliable contact through the elastic deformation of the protrusions
Data Source
AI summary
A ground contact connecting member comprises a support portion and a plurality of contacting beams. The support portion extends in a first direction and is adapted to be fixed to an installation portion of a connector housing. The plurality of contacting beams extend from the support portion in a second direction, perpendicular to the first direction. The contacting beams are adapted to contact a plurality of ground contacts arranged in the connector housing in a third direction perpendicular to the first direction and the second direction.