Modular Electrical Connector Assembly with Interchangeable End Members
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Solution Overview
Problem
The rapid evolution of electronic devices necessitates new electrical connectors to handle increasing data rates and changing power requirements, but designing and manufacturing these connectors is expensive and time-consuming, requiring significant tooling changes and facility reconfigurations.
Innovation Solution
The development of an electrical connector system comprising a power connector housing and a signal connector housing, each with elongate receptacles and end members that can be easily coupled and uncoupled to facilitate quick assembly and reconfiguration, allowing for efficient adaptation to evolving device needs without extensive retooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If new electrical connectors are designed to handle increasing data rates and changing power requirements, then the adaptability and performance of electronic devices are improved, but the manufacturing cost and time consumption increase due to required tooling changes and facility reconfigurations
Solution Approach 1:
The electrical connector is divided into separate modular components: a first connector housing with power contacts, a second connector housing with signal contacts, and interchangeable end members. This segmentation allows individual components to be manufactured independently using existing tooling, while enabling reconfiguration through assembly of different end members to various housing types, thus achieving adaptability without requiring complete retooling of the manufacturing process
Solution Approach 2:
The connector housings are designed with universal interfaces that can accept different types of end members. The first connector housing can be coupled with different end members to create connectors suitable for various power requirements, and similarly for signal connectors. This multi-functionality allows a single housing design to serve multiple applications, reducing the need for specialized tooling for each connector variant
2Strength
If traditional electrical connectors are manufactured with integrated housings, then structural integrity is maintained, but the time and cost for updating connector designs increases due to required facility reconfigurations
Solution Approach 1:
The connector is segmented into permanent housing components that provide structural integrity and interchangeable end members that enable design updates. The housing portions can be manufactured once and reused, while only the end members need to be redesigned for new applications, significantly reducing update time while maintaining the structural strength of the overall connector assembly
Solution Approach 2:
The connector design transitions from a static integrated structure to a dynamic modular system where end members can be coupled and uncoupled from the housings. This dynamic capability allows the connector to adapt to new requirements by simply replacing end members rather than redesigning the entire structure, reducing update time while preserving the structural integrity of the housing components
3Ease of manufacture
If electrical connectors are designed as single integrated units, then manufacturing simplicity is maintained, but adaptability to evolving device needs is reduced
Solution Approach 1:
The connector is segmented into standardized housing components and interchangeable end members that can be manufactured using existing processes. The housings maintain manufacturing simplicity through standardized designs, while the ability to couple different end members to these housings provides adaptability to evolving device needs without compromising manufacturing ease
Solution Approach 2:
The connector housing serves as an intermediary component that bridges the manufacturing simplicity of standardized designs with the adaptability requirements of evolving applications. By designing the housing with universal coupling interfaces, it mediates between the simplicity of producing a single housing design and the need to support multiple connector configurations through interchangeable end members
Data Source
AI summary
An electrical assembly can include one or more electrical connectors. Each electrical connector can include at least a first connector housing supporting a plurality of electrical power contacts and a second connector housing supporting a plurality of electrical signal contacts. Each of the first and second connector housings can define respective receptacles that are open on respective opposed sides of the first and second connector housings. Each electrical connector can further include at least one, such as a plurality of closure members configured to close the receptacles at respective lateral sides of the first and second connector housings. The closure members of the first and second electrical connectors can comprise at least one or all of end members, interconnect members, and spacer members.