Longitudinal Connector Layout for More Contacts in Tight Spaces
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Solution Overview
Problem
Standard multi-contact electrical connectors are too large in diameter to pass through confined spaces in aircraft, necessitating unattached conductors and on-site termination, which increases assembly time and cost.
Innovation Solution
A longitudinally expandable electrical connector assembly that accommodates increasing numbers of conductors without expanding the cross-sectional area by using longitudinally disposed insulator modules and PCBs, allowing for additional termination points along the length of the connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of contacts in a connector is increased, then the connector can accommodate more conductors, but the diameter of the connector increases
Solution Approach 1:
The patent transitions from a radial arrangement of contacts (increasing diameter) to a longitudinal arrangement of contacts (increasing length). The connector housing extends in the longitudinal direction with contacts arranged along the length rather than around the circumference, allowing more contacts without increasing the cross-sectional area.
Solution Approach 2:
The connector is divided into multiple sections or modules along its length, with each section containing a subset of contacts. This segmentation allows the total number of contacts to be distributed along the longitudinal axis, enabling scalability without proportional increase in diameter.
2Area of moving object
If the diameter of the connector is reduced to fit through confined spaces, then the connector can pass through openings, but the number of contacts must be reduced
Solution Approach 1:
The patent resolves this contradiction by moving the scaling dimension from radial (diameter) to longitudinal (length). The connector maintains a compact cross-sectional area suitable for confined spaces while achieving high contact density through extended length, effectively trading radial space for axial space.
3Adaptability or versatility
If on-site termination is performed to accommodate routed cables, then the connector can be customized, but assembly time and cost increase
Solution Approach 1:
The connector is designed with pre-configured contact arrangements and predetermined contact positions along its length. This preliminary configuration allows the connector to be customized for different applications during the manufacturing process rather than requiring on-site termination, reducing assembly time while maintaining adaptability.
Data Source
Figure 1
Figure 2A~3
Figure 2C~4
AI summary
An electrical connector assembly including a plug having an open end and an inner shell that extends distally to an elongate partial tubular mounting portion, and a complementary receptacle similarly configured so as to form an enclosure with the plug when mated. Each of the plug and receptacle include a longitudinally oriented contact array having a plurality of termination points for terminating conductors and a plurality of contacts for matable electrical contact with the other connector member. A locking feature locks the plug and receptacle in a mated configuration. The connector facilitates the termination of additional conductors without the need to expand the outer diameter or circumference of the connector housings.