Keyed Electrical Connector Assembly for Precise PCB Alignment
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Solution Overview
Problem
Existing electrical connector assemblies lack efficient engagement mechanisms between plug and receptacle connectors, leading to potential misalignment and incomplete circuit formation.
Innovation Solution
The assembly includes a plug connector with a plug housing, front and rear terminals, and upper and lower cables, and a mating receptacle connector with front and rear contacts, all secured to a PCB, featuring keyed surfaces and interference fits to ensure precise alignment and secure engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing engagement mechanisms are used between plug and receptacle connectors, then the device complexity is reduced, but the alignment precision and circuit formation reliability deteriorate
Solution Approach 1:
The patent employs asymmetric keyed surfaces on the plug housing and receptacle housing that engage in a specific directional orientation. The keyed surface on the plug housing includes a first portion and a second portion with different geometries that correspond to complementary surfaces on the receptacle, ensuring precise alignment while preventing misorientation. This asymmetric design provides unique engagement geometry that achieves high alignment precision without requiring complex adjustment mechanisms.
Solution Approach 2:
The engagement mechanism performs preliminary alignment actions through the keyed surfaces before final contact establishment. The keyed surface geometry is designed to guide the plug and receptacle into proper alignment during the engagement process, automatically correcting minor positioning errors. This preliminary alignment action occurs as the connectors approach each other, ensuring precise positioning before the electrical contacts make full engagement.
2Reliability
If simple engagement mechanisms are used, then the ease of operation is improved, but the circuit formation completeness and signal integrity deteriorate
Solution Approach 1:
The asymmetric keyed surfaces provide automatic orientation guidance that simplifies the engagement operation. The unique geometric profile on each keyed surface acts as a mechanical guide, allowing the connector to self-align during insertion. This eliminates the need for complex alignment procedures or specialized tools, making the operation simple while ensuring reliable circuit formation through precise positioning.
Solution Approach 2:
The engagement mechanism is designed to self-align and self-correct during the connection process. The keyed surface geometry automatically guides the plug and receptacle into proper alignment without external intervention. The mechanical features perform the alignment function autonomously as the connectors engage, ensuring reliable circuit formation while maintaining ease of operation.
3Manufacturing precision
If precise alignment features are added to ensure complete circuit formation, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The keyed surfaces utilize asymmetric geometric profiles that are integrated into the housing structures. The first and second portions of the keyed surface on the plug housing engage with corresponding asymmetric surfaces on the receptacle, providing precise alignment through the inherent geometry rather than requiring separate adjustment mechanisms. This approach achieves high manufacturing precision while minimizing additional structural complexity.
Solution Approach 2:
The alignment features are merged with the housing structures themselves rather than being separate components. The keyed surfaces are formed as integral parts of the plug and receptacle housings, combining the alignment function with the structural housing elements. This integration reduces the number of discrete parts and simplifies the overall device complexity while maintaining precise alignment capability.
Data Source
AI summary
An electrical connector assembly includes: a plug connector including a plug housing, a front terminal and a rear terminal both secured to the plug housing, and an upper cable connected to the front terminal and a lower cable connected to the rear terminal; and a mating receptacle connector including a receptacle housing and a front contact and a rear contact both secured to the receptacle housing, wherein the plug housing engages the receptacle housing and the front terminal engages the front contact and the rear terminal engages the rear contact.