Modular Connector Assembly With Floating Alignment
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Solution Overview
Problem
Existing electrical connectors face limitations in power capability and size, requiring larger connectors for increased power, which increases manufacturing costs and space usage, and often require direct line-of-sight alignment, restricting versatility and efficiency in connecting multiple electrical circuits.
Innovation Solution
A connector assembly comprising a system connector and a module connector with power and signal contacts, separated by extensions for alignment and mating, allowing for high voltage and current ratings while maintaining a compact size and enabling blind coupling due to floating assemblies, facilitating alignment and connection across different systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the connector size is increased to handle higher electrical power, then the power capability is improved, but the manufacturing cost and space usage increase
Solution Approach 1:
The connector is divided into modular components including a housing, bracket, and multiple contact assemblies that can be separately manufactured and assembled. This segmentation allows for optimized power transmission paths while maintaining a compact overall structure, resolving the contradiction between power capability and size.
Solution Approach 2:
The connector utilizes three-dimensional contact arrangements with contacts positioned at different heights and angles within the housing. This dimensional optimization allows multiple power contacts to be packed efficiently in a compact volume, achieving high power capability without proportional size increase.
2Manufacturing precision
If direct line-of-sight alignment is required for connector assembly, then the alignment precision is improved, but the ease of operation and versatility deteriorate
Solution Approach 1:
Alignment features such as guide pins, tapered interfaces, and keyed slots are pre-formed during manufacturing. These preliminary alignment structures automatically guide the connector components into proper alignment during assembly, eliminating the need for manual line-of-sight alignment while maintaining high precision.
Solution Approach 2:
The connector incorporates self-aligning mechanisms where the geometry of the housing and bracket automatically position contacts during mating. The design allows the connector to align itself through mechanical interference and geometric constraints, improving ease of operation without sacrificing alignment precision.
Data Source
AI summary
A connector assembly includes a system connector having a system housing and a system bracket coupled with the system housing. The system bracket includes plural system power contact receptors that receive plural system power contacts. The plural system power contacts are separate from each other by one or more extensions coupled with the system bracket. A module connector is coupled with the system connector. The module connector includes a module housing and a module bracket coupled with the module housing. The module bracket includes plural module power contact receptors that receive plural module power contacts. Each of the plural module power contacts are separated from each other by one or more extensions coupled with the module bracket. Each of the plural system power contacts of the system bracket are configured to mate with one of the plural module power contacts of the module bracket as plural power contact assemblies.