Hybrid Electrical Connector with Segmented Contact Units
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Solution Overview
Problem
Traditional electrical connectors with single-piece contacts face challenges in achieving a balance between mechanical and electrical performance, particularly in fine pitch arrangements, where mechanical characteristics like mating normal force and electrical characteristics like lower impedance are difficult to optimize simultaneously.
Innovation Solution
The electrical connector design features a contact unit comprising two parts: a spring contacting section for superior mechanical resiliency and a mounting section soldered onto the printed circuit board, with the latter providing lower impedance and strong retention, both derived from sheet metal via stamping and forming, where the first part is thinner and the second part is thicker for enhanced conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional one-piece contact is used, then the structure is simple and easy to manufacture, but it is difficult to achieve both superior mechanical resiliency and lower impedance simultaneously
Solution Approach 1:
The contact is divided into two separate parts: a first part (contact portion) that provides mechanical resiliency and a second part (mounting portion) that provides electrical conductivity and retention. This segmentation allows each part to be optimized for its specific function, resolving the contradiction between manufacturing simplicity and performance balance.
Solution Approach 2:
The contact uses composite construction with two different metal materials having distinct properties. The first part uses a material optimized for elasticity and mechanical contact, while the second part uses a material optimized for electrical conductivity and solderability. This composite approach enables simultaneous achievement of superior mechanical and electrical characteristics.
2Productivity
If the contact is designed for fine pitch arrangement, then the electrical connection density is improved, but the mechanical performance and impedance control become more difficult to balance
Solution Approach 1:
By segmenting the contact into specialized first and second parts, each optimized for specific functions, the design achieves fine pitch arrangement capability while maintaining mechanical resiliency and impedance control. The first part handles mechanical contact at fine pitches, while the second part ensures proper electrical connection and retention.
Solution Approach 2:
Different portions of the contact have different material properties and structural characteristics tailored to their specific functions. The first part has properties optimized for mechanical contact and resiliency, while the second part has properties optimized for electrical conductivity and soldering, enabling fine pitch performance with controlled impedance.
3Force
If the contact provides strong mechanical retention, then the mating normal force is improved, but the impedance may increase
Solution Approach 1:
The contact is segmented so that the first part (contact portion) is responsible for providing mechanical resiliency and mating normal force, while the second part (mounting portion) is responsible for providing low impedance and electrical retention. This functional separation resolves the contradiction between mechanical force and impedance control.
Solution Approach 2:
The contact features local quality differentiation where the first part has material and structural properties optimized for mechanical force generation, while the second part has properties optimized for electrical conductivity and impedance reduction. This localized optimization allows simultaneous achievement of strong mechanical retention and low impedance.
Data Source
AI summary
An electrical connector includes a plurality of contact units each having a first part and a second part mechanically and electrically connected to each other wherein the first part provides the spring contacting section for performing the superior mechanical resiliency while the second part provides the mounting section soldered upon the printed circuit board and configured to lower the impedance compared with the first part and provide strong retention thereof.