Low Profile Connector Spring Contacts Depth Reduction
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Solution Overview
Problem
Traditional connector assemblies for rearview devices are bulky, consuming more interior cabin space and weight, and often require manual connection of wire harnesses, which can lead to issues like sagging or drooping over time.
Innovation Solution
A low-profile connector assembly with spring contacts that directly engage electrical leads, minimizing the depth of the housing and allowing for a sleek design, where spring-biased contacts are compressed between the circuit board and the connector body, providing a secure and compact electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If traditional connector assemblies are used, then electrical connection is achieved, but the housing depth increases and bulk is created
Solution Approach 1:
The connector employs spring-biased contacts that dynamically adjust to maintain reliable electrical connection. The spring mechanism allows the contacts to flex and self-adjust, ensuring continuous contact pressure despite variations in assembly tolerances or thermal expansion, thereby maintaining connection reliability in a shallow housing configuration.
Solution Approach 2:
The invention changes the physical state and configuration of the electrical connection by using compressed spring contacts instead of rigid connectors. This parameter change allows the connector to achieve both shallow depth and reliable connection through the elastic deformation and continuous contact pressure provided by the spring mechanism.
2Weight of moving object
If traditional connector assemblies are used, then electrical connection is achieved, but weight increases
Solution Approach 1:
The connector utilizes flexible spring contacts that can be made from thin, lightweight materials while maintaining structural integrity and electrical conductivity. The spring design allows for reliable connection with minimal material usage, reducing overall weight compared to traditional rigid connector assemblies.
3Ease of manufacture
If manual wire harness plugging is required, then connection is achieved, but installation complexity and potential for sagging increases
Solution Approach 1:
The spring-biased connector design enables self-aligning and self-latching functionality. The spring contacts automatically engage with the electrical leads upon insertion, eliminating the need for manual plugging or adjustment. This self-service mechanism ensures stable connection without requiring installer skill or subsequent adjustments, preventing sagging and maintaining composition stability.
4Length of stationary object
If low-profile design is implemented, then housing depth is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The spring mechanism provides dynamic adjustment capability that compensates for manufacturing tolerances. The elastic nature of the spring contacts allows them to self-align and adapt to slight misalignments, reducing the stringency of manufacturing precision requirements while maintaining the low-profile housing depth.
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 low-profile design reduces the overall depth of the rearview device, minimizing bulk and weight, while ensuring a secure and efficient electrical connection without the need for manual wire harness plugging, thus enhancing packaging and aesthetics.
Implementation Method 1
The plurality of spring contacts abut and are compressed between the circuit board and the body
Data Source
AI summary
A rearview device includes a connector assembly that has a body that includes a plurality of electrical leads that extend therefrom and are removably coupled therewith. A plurality of contact-receiving apertures extend through the body and receive a plurality of spring contacts on a circuit board. The plurality of spring contacts abut and are compressed between the circuit board and the body. The plurality of spring contacts directly engage the plurality of electrical leads when inserted into the plurality of contact-receiving apertures. A plurality of peripheral walls are adjacent the circuit board.