Perpendicular Electrical Connector for Circuit Card Airflow
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Solution Overview
Problem
Conventional communication systems face challenges in allowing airflow for cooling due to the use of expensive and space-occupying right-angle electrical connectors, which obstruct airflow and can lead to overheating.
Innovation Solution
The design of an electrical connector for circuit card assemblies featuring a receptacle housing and a mating housing with flexible conductors that allow relative movement, enabling perpendicular mating and reducing the connector's dimensions, thus allowing greater airflow while maintaining electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If right angle electrical connectors are used to enable orthogonal mating of circuit cards, then reliable electrical connection is achieved, but the connector occupies large space and blocks airflow causing overheating
Solution Approach 1:
The contact modules are designed to be movable relative to the receptacle housing during the mating process. The mating housing moves in the connector mating direction to engage the contacts, allowing the connector to adapt dynamically during assembly while maintaining a compact form factor that does not block airflow
Solution Approach 2:
The connector utilizes a perpendicular mating direction relative to the board loading direction. The mating housing moves perpendicular to the PCB insertion direction, allowing the electrical connection to be established in a different dimensional plane, thus reducing the space occupied along the airflow path
2Adaptability or versatility
If right angle electrical connectors are used for orthogonal mating, then circuit cards can be connected perpendicularly, but manufacturing cost increases
Solution Approach 1:
The electrical connector is divided into separate functional modules: the receptacle housing mounted on the PCB, the mating housing that moves independently, and the contact modules that bridge between them. This segmentation allows each component to be manufactured separately using standard processes and assembled through perpendicular insertion, reducing overall manufacturing complexity and cost
Solution Approach 2:
The mating housing is received within the receptacle housing, with the mating end of the mating housing engaging the contact modules that are coupled to the receptacle housing. This nested arrangement achieves orthogonal mating capability while using compact, cost-effective housing structures rather than expensive custom right-angle connector assemblies
3Reliability
If conventional electrical connectors are used, then electrical connectivity is maintained, but airflow is blocked leading to system overheating
Solution Approach 1:
The connector establishes electrical connectivity through perpendicular mating (mating direction perpendicular to board loading direction), which reduces the footprint along the horizontal airflow path. This dimensional change allows airflow to pass through the system more freely while maintaining reliable electrical connections between circuit cards
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
This solution reduces the physical dimensions of the connectors, enhancing airflow and cooling within the communication system while ensuring reliable electrical connections, thereby improving system efficiency and reducing costs.
Implementation Method 1
The flexible conductors extend between the inner dielectric body and the outer dielectric body and are flexible therebetween to allow relative movement of the inner dielectric body and the mating housing in the connector mating direction relative to the outer dielectric body and the receptacle housing
Data Source
AI summary
An electrical connector for a circuit card assembly includes a receptacle housing and a mating housing movable relative to the receptacle housing in a connector mating direction. The electrical connector includes contact modules each having a leadframe having signal contacts with a mating conductor, a mounting conductor and a flexible conductor between the mating conductor and the mounting conductor. Each contact module includes an inner dielectric body and an outer dielectric body separate and discrete from the inner dielectric body. The flexible conductors extend between the inner and outer dielectric bodies to allow relative movement of the inner dielectric body in the connector mating direction relative to the outer dielectric body.