Hybrid Electrical Connector With Restrained Contacts for Vibration Reliability
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Solution Overview
Problem
Existing electrical connectors face challenges in maintaining mechanical reliability and compactness while supporting both power and high-speed signals, particularly under conditions of vibration and frequent mating/unmating.
Innovation Solution
The use of a hybrid electrical connector design that incorporates an insulative member with specific channel configurations to restrain conductive elements, combined with resilient latch arms and protrusions for secure retention within the connector housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conductive elements are made flexible to allow frequent mating/unmating, then ease of operation is improved, but mechanical reliability deteriorates due to increased risk of damage under vibration
Solution Approach 1:
The conductive element is divided into multiple segments including a head portion, intermediate portion, and tail portion. The intermediate portion is positioned within recesses of the insulative member, allowing relative movement during mating/unmating while the head and tail portions remain securely retained, thus enabling frequent operation without compromising mechanical reliability
Solution Approach 2:
The insulative member acts as an intermediary structure that houses and guides the conductive element. The recesses in the insulative member provide a controlled environment for the intermediate portion of the conductive element, allowing necessary movement while preventing excessive displacement that could cause damage under vibration conditions
2Area of stationary object
If the connector design is made compact to reduce footprint, then device complexity is reduced, but manufacturing precision requirements increase due to tighter tolerances
Solution Approach 1:
The conductive element is nested within the insulative member, with the intermediate portion positioned within recesses and the tail portion extending through openings. This nested configuration allows for a compact overall structure while maintaining adequate spacing and alignment through the hierarchical arrangement of components
Solution Approach 2:
The design utilizes three-dimensional positioning of the conductive element within the insulative member, with the intermediate portion located in recesses and the tail portion extending through openings in specific directions. This spatial arrangement achieves compact footprint while maintaining manufacturing tolerances through optimized dimensional relationships
3Reliability
If resilient latch arms are added to secure conductive elements, then reliability is improved, but device complexity increases due to additional components
Solution Approach 1:
The resilient latch arms are integrated with the insulative member as a unified structure rather than separate components. The latch arms extend from the insulative member and work in conjunction with the recesses and openings to secure the conductive element, reducing overall device complexity while maintaining reliable retention
Solution Approach 2:
The resilient latch arms provide automatic retention of the conductive element through their elastic properties. The arms naturally engage with the conductive element and maintain securing force without requiring additional actuation mechanisms or complex control systems, achieving reliable retention with minimal added complexity
Data Source
AI summary
Reliable hybrid electrical connectors are provided. A connector can have conductive elements each having a mating end, a tail end, and an intermediate portion joining the mating end and the tail end. The intermediate portion comprises a curved portion, a first straight portion joining the curved portion and the mating end, and a second straight portion joining the curved portion and the tail end. A connector housing comprises a body having a front, mating face and a rear face, and first and second arms extending from the rear face of the body and away from the mating face. An insulative member is disposed between the first and second arms of the housing and holds at least a portion of the second straight portion of the intermediate portion of each conductive element. The insulative member can be configured to restrain movements of the conductive elements, improving the reliability of the connector.