Multi-Channel Connector with Resilient Annular Contacts
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Solution Overview
Problem
Conventional multi-channel electrical connectors face issues with insecure interengagement due to wear and oxide buildup, complexity in manufacture, and limited rotational compatibility, leading to intermittent or permanent electrical path disruptions.
Innovation Solution
A multi-channel electrical connector utilizing resilient annular contact elements under compression and expansion, with conductive regions formed by discrete areas of coated electrically conductive material on insulating substrates, allowing secure and flexible electrical connections in any rotational setting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pins and sleeves are used for electrical connection, then the connector structure is simple, but the interengagement becomes insecure due to wear and oxide buildup
Solution Approach 1:
A resilient contact element is introduced as an intermediary between the pin and socket. This contact element deforms elastically to maintain secure electrical connection, compensating for wear and oxide buildup while distributing mechanical stress, thereby preventing direct wear between pin and socket surfaces.
Solution Approach 2:
The contact element's mechanical properties are optimized by selecting appropriate material and dimensions. The resilience parameter is tuned so that the contact element deforms under compression to maintain constant electrical pressure, adapting to varying connection conditions while preserving connection security.
2Reliability
If precision production and positional fixing of pins and sleeves are implemented, then electrical connection security improves, but manufacturing complexity increases
Solution Approach 1:
The contact element automatically positions itself within the socket groove through elastic deformation. The resilient nature of the contact element allows it to self-align and maintain optimal contact position with the pin, eliminating the need for precision fixing mechanisms during manufacturing.
Solution Approach 2:
The connector is divided into modular components: the socket body with grooves, the resilient contact elements, and the pin. This segmentation allows each component to be manufactured independently with standard tolerances, reducing overall manufacturing complexity while maintaining connection reliability through the resilient interface.
3Manufacturing precision
If specific relative rotational relationships are enforced between plug and socket, then electrical connection precision improves, but operational flexibility deteriorates
Solution Approach 1:
The contact elements and contact surfaces are designed with circular/annular geometries that are inherently rotationally symmetric. This allows the pin and socket to be connected at any rotational orientation while maintaining consistent electrical contact, as the circular contact paths ensure uniform pressure distribution regardless of rotation angle.
4Reliability
If multiple separate conductive components are used, then electrical connection reliability improves, but device complexity and cost increase
Solution Approach 1:
Multiple conductive functions are merged into the resilient contact element, which simultaneously serves as an electrical conductor, a mechanical spring, and a positioning element. This integration reduces the number of separate components while maintaining reliable electrical connection through the resilient contact mechanism.
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 solution provides a secure, simple, and compact electrical connection resistant to unintended interruptions, with reduced manufacturing complexity and cost, enabling reliable multiple-channel connections across various rotational relationships.
Implementation Method 1
resilient contact elements, which in the presence of the pin in the bore of the socket body are subjected to loading under compression in the annular grooves of the socket body and loading under expansion by the annular contact zones of the pin
Implementation Method 2
These two sources of spring loading, provided by initial location of the contact element in the groove at the time of manufacture of the connector and by engagement of the pin in the bore during use of the connector
Implementation Method 3
the formation of at least some of the electrically conductive regions of the socket body and/or plug body by discrete areas of electrically conductive material coated on the electrically insulating material of the relevant body
Data Source
Figure 1A~1E
Figure 2A~2E
Figure 3
AI summary
A multi-channel electrical connector comprises a socket and a plug, which each comprise a body 21, 31 of electrically insulating material. The socket body has a bore 22 with a plurality of annular spaced-apart grooves 24 each having an electrically conductive surface and each receiving a resilient electrically conductive annular contact element 27 such as a canted coil spring 27a. The socket body is further provided with a plurality of electrical conductors 25 each electrically connected with one of the grooves and each terminating in an electrical terminal 26. The plug body comprises a pin 33 which is insertable into the bore and which is provided at its circumference with a plurality of spaced-apart electrically conductive annular contact zones (35, Fig 2A). Similarly to the socket body, the plug body is further provided with a plurality of electrical conductors 36 each electrically connected with a respective one of the contact zones and each terminating in an electrical terminal (37, Fig 2D). The conductive areas may be made by completely plating the insulating body and grinding away the unrequired areas.