Multi-Width Electrical Connector for Blind-Mating Alignment
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Solution Overview
Problem
Miniaturized electrical connectors are susceptible to damage from misalignment and improper force application during blind mating, leading to signal and power transmission failures.
Innovation Solution
The development of electrical connectors with multiple segments of varying widths and latching mechanisms to ensure proper alignment and secure mating, minimizing misalignment and improper force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If electrical connectors are miniaturized to meet demand for smaller portable electronics, then the size and weight of connectors are reduced, but the structural integrity and susceptibility to damage during handling and mating operations deteriorate
Solution Approach 1:
The connector is divided into multiple segments including a main body, a neck segment, and a mating portion. The neck segment acts as a transition zone that distributes mechanical stress, preventing concentration of forces that could damage fragile internal elements during blind mating operations
Solution Approach 2:
The neck segment is designed with increased thickness and reinforced structure to serve as a cushioning element before the mating portion. This pre-positioned structural reinforcement absorbs and distributes impact forces during insertion, protecting the delicate internal connector elements from damage
2Volume of moving object
If electrical connectors are miniaturized, then the size of connectors is reduced, but the susceptibility to misalignment and misorientation during blind mating increases
Solution Approach 1:
The connector employs asymmetric design features including a non-uniform neck segment profile and asymmetric positioning of contact portions. These asymmetric characteristics create a unique geometric signature that guides proper orientation during blind mating, preventing misalignment and incorrect insertion
3Weight of moving object
If connectors are made thinner and lighter, then portability is improved, but the ability to withstand improper force application during mating deteriorates
Solution Approach 1:
The neck segment serves as a pre-positioned cushioning structure that absorbs and distributes improper forces applied during mating operations. This allows the rest of the connector to remain thin and lightweight while the strategically placed neck segment provides the necessary mechanical protection
Solution Approach 2:
By segmenting the connector into distinct functional zones (main body, neck segment, mating portion), the design allows the neck segment to be optimized for strength and force distribution, while other portions can be minimized for weight, achieving a balance between lightness and durability
Data Source
AI summary
An electrical connector includes an insulative housing, metal terminals, and a metal shell. The terminals may be disposed in the housing such that contact portions of the terminals are exposed in openings of the housing and are arranged to contact conductive portions of a mating connector when the electrical connector and the mating connector are mated. The shell may surround external surfaces of the housing and may include a first and second portions separated by a third portion. The third portion may a width that is less than those of the first and second portions, such that a shape of the shell may include at least one recess positioned between the first and second portions. Portions of the shell may be spaced apart from the housing to define plugging spaces configured to receive legs of the mating connector.