Modular Pass-Through Inserts for High-Cycle Mass Interconnects
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing high-speed data contact systems are not adapted for high life cycle systems that require thousands or tens of thousands of connection cycles and do not efficiently allow for the replacement of worn contacts without disassembling the module.
Innovation Solution
A modular interface system with pass-through inserts that can be secured and replaced from the front, using latches on opposite sides, allowing for simultaneous use of multiple contact types (high-speed data, power, signal) and enabling easy replacement of contacts that are subject to repetitive mating and un-mating cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional high-speed data contact systems are used, then the system structure is simple, but the system cannot achieve high life cycle requirements of thousands or tens of thousands of connection cycles
Solution Approach 1:
The contact system is divided into multiple independent contact sets (e.g., first contact set, second contact set, third contact set) that can be independently replaced. Each contact set is housed in its own housing, allowing selective replacement of worn contacts without replacing the entire system, thereby extending the overall system life cycle while maintaining manageable complexity.
Solution Approach 2:
The contact sets are extracted from the main system housing and placed in separate replaceable housings. This allows the contacts subject to repetitive mating and un-mating cycles to be removed and replaced independently, extending the life cycle of the system while keeping the replacement process simple and targeted.
2Ease of repair
If contacts are replaced by disassembling the module, then worn contacts can be replaced, but the replacement process is time-consuming and complex
Solution Approach 1:
The module is segmented into a main housing and separate contact sets housed in individual housings. This segmentation allows contact sets to be replaced independently by simply detaching the affected housing from the front of the module, eliminating the need to disassemble the entire module and significantly reducing replacement time and complexity.
Solution Approach 2:
The contact sets are extracted into separate removable housings that can be detached from the front of the module. This extraction enables maintenance personnel to replace worn contacts by simply removing and replacing the entire housing containing the contact set, without needing to access or disassemble internal components of the module.
3Adaptability or versatility
If multiple contact types are used simultaneously, then the interface functionality is enhanced, but the complexity of the module increases
Solution Approach 1:
Different contact types (e.g., high-speed data contacts, power contacts, signal contacts) are segregated into separate contact sets housed in individual housings. This segmentation allows each contact type to be optimized independently while maintaining overall system versatility, and enables selective replacement of only the contact types that require it, managing complexity through modular organization.
Solution Approach 2:
The module is designed with universal mounting structures and standardized interfaces that can accommodate multiple types of contact sets (first, second, and third contact sets with different contact types). This universality allows the system to perform multiple functions with different contact types while maintaining a consistent, manageable structural framework.
Data Source
AI summary
An interface having a frame with a plurality of slots, a first pass-through insert in the frame and a second pass-through insert in the frame. The first pass-through insert and the second pass-through insert each have a housing and a contact with the type of contact in the first pass-through insert is different than the type of contact in the second pass-through housing.