Modular Connector Misalignment Tolerance via Segmented Float
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Solution Overview
Problem
Existing connector systems for circuit boards face challenges in accommodating misalignment tolerances and facilitating modular connections between adapter and header assemblies, particularly in blind mating scenarios.
Innovation Solution
A modular connector assembly system comprising adapter and header assemblies with insulators and contacts that allow for 0.62 mm axial and +/-0.75 mm radial mis-alignment tolerances, featuring float plates and beveled edges for alignment facilitation, enabling flexible and adaptable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional rigid connector systems are used, then manufacturing precision can be maintained, but misalignment tolerance during blind mating is poor
Solution Approach 1:
The connector system is divided into separate adapter and header assemblies that can be manufactured independently with high precision, then connected through blind mating. The adapter assembly includes an adapter housing with insulator and contacts, while the header assembly includes a header housing with insulator and contacts. This segmentation allows each component to be precisely manufactured separately while the modular design accommodates misalignment during assembly.
Solution Approach 2:
The patent employs floating contacts within the insulators that can move axially and radially to compensate for misalignment. The contacts are designed with floating mechanisms that allow them to adjust their position, providing 0.62 mm axial and +/-0.75 mm radial misalignment tolerances. This parameter change enables the connector to maintain reliable electrical connection despite positioning variations during blind mating.
2Adaptability or versatility
If modular adapter assemblies are introduced, then adaptability and flexibility are improved, but device complexity increases
Solution Approach 1:
The adapter assembly is designed as a universal component that can connect to different header assemblies and circuit board configurations. The adapter housing with its insulator and contact arrangement can be adapted to various applications by changing the header assembly or circuit board layout. This universality allows the same adapter design to serve multiple functions and configurations, improving adaptability without proportionally increasing complexity.
Solution Approach 2:
The insulator is nested within the housing, and contacts are nested within the insulator, creating a compact hierarchical structure. The adapter housing contains the insulator, which in turn contains the contacts. This nested arrangement consolidates multiple components into a space-efficient modular unit, improving adaptability while managing complexity through integrated design rather than separate discrete parts.
3Reliability
If floating contacts with misalignment tolerance are implemented, then blind mate reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The contacts are designed to self-align and self-adjust through floating mechanisms within the insulator. During assembly, the contacts automatically position themselves to accommodate misalignment without requiring precise manual adjustment or complex alignment procedures. This self-service capability improves connection reliability under misalignment while simplifying the manufacturing and assembly process by eliminating the need for complex alignment fixtures or procedures.
Data Source
AI summary
The present invention provides a modular connector system for, in some embodiments, interconnecting circuit boards. In some embodiments, the modular connector system includes a header assembly for blind mating with an adapter assembly.