High Density Connector With Stacked Terminal Modules
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Solution Overview
Problem
Conventional high density electrical connectors are difficult to connect to individual conductors and costly to repair, especially in applications requiring over 50 contacts with high contact density, and often lack effective magnetic shielding and ease of sterilization.
Innovation Solution
A high density pluggable electrical connector system with a casing and terminal unit featuring stacked terminal modules, spring plugging contact portions, and a connection board with magnetic shielding, allowing easy interconnection and repair, and accommodating various connection techniques and magnetic field shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional high density electrical connectors are used to achieve high contact density, then the number of electrical contacts per unit area increases, but the difficulty of connecting to individual conductors and repairing faulty interconnections increases
Solution Approach 1:
The connector is divided into multiple terminal modules, each containing a subset of electrical contacts. This segmentation allows individual modules to be accessed, tested, and replaced independently, making connection and repair operations feasible even when the total number of contacts exceeds one hundred.
Solution Approach 2:
The electrical contacts are arranged in a three-dimensional stacked configuration rather than a planar arrangement. Multiple layers of terminal modules are stacked vertically within the connector housing, enabling high contact density while maintaining accessibility through modular design.
2Area of stationary object
If the number of electrical contacts exceeds one hundred with high contact density, then the connector size is reduced, but the difficulty of testing and repair increases
Solution Approach 1:
The connector is divided into multiple terminal modules, each containing a subset of electrical contacts. This segmentation allows individual modules to be accessed, tested, and replaced independently, making connection and repair operations feasible even when the total number of contacts exceeds one hundred.
Solution Approach 2:
Terminal modules are nested within the connector housing in a stacked arrangement, with each module containing contacts, connection boards, and associated components. This nested structure maximizes space utilization while maintaining modular accessibility for testing and repair.
3Object-affected harmful factors
If magnetic shielding is added to protect electrical contacts from strong magnetic fields, then shielding effectiveness increases, but the size and complexity of the connector increases
Solution Approach 1:
The magnetic shielding function is integrated into the terminal module housing structure itself rather than being added as a separate external component. The housing incorporates magnetic shielding material or magnetic shielding features that protect the electrical contacts while maintaining a compact overall connector size.
Solution Approach 2:
The terminal modules with integrated magnetic shielding are nested within the connector housing in a stacked arrangement. This nested structure allows the magnetic shielding to be incorporated within the existing form factor without significantly increasing the overall connector dimensions.
4Area of stationary object
If high density electrical connector is designed for compact size, then the overall diameter is reduced, but the ease of manufacturing and assembly decreases
Solution Approach 1:
The connector is divided into multiple terminal modules that can be manufactured independently using standardized processes. Each module contains a manageable number of contacts and connection boards, making assembly feasible despite the high overall contact density.
Solution Approach 2:
The terminal modules are designed with universal interfaces and standardized configurations that can be assembled in a stacked arrangement. This modularity allows for easier manufacturing and assembly compared to a monolithic high-density connector design.
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
The system enables reliable, high-density electrical connections with easy testing and repair, cost-effective manufacturing, and magnetic shielding, suitable for applications like medical equipment and MRI environments, while maintaining a compact size.
Implementation Method 1
The contacts of each terminal module comprise spring plugging contact portions arranged in two rows forming a receptacle slot configured for receiving a male contact arrangement of a mating connector therein
Implementation Method 2
In an embodiment, at least one of the terminal modules comprises a magnetic shield surrounding the terminal module housing
Data Source
AI summary
High density pluggable electrical connector having a number of electrical contacts exceeding sixty and a contact density on a plugging interface of the connector of at least forty contacts per square centimeter, comprising a casing and a terminal unit mounted within the casing, the terminal unit comprising a housing with a module receiving cavity formed within the housing, and a plurality of terminal modules insertably received in the module receiving cavity in a stacked arrangement. Each terminal module comprises a plurality of contacts mounted in a dielectric terminal module housing, the terminal modules having a width W to height H ratio W/H greater than three.