Power Microconnector With Inclined Support And Segmented Housing
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Solution Overview
Problem
Existing electrical connector systems for power distribution in electronic systems face issues such as large size, high contact resistance, rapid wear, and difficulty in assessing connection quality.
Innovation Solution
A compact electrical connector design featuring a housing with an inclined support for flat metal bars, immobilization via clipping tabs and bosses, and treated end portions for reduced contact resistance, ensuring a flat and durable electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional connector systems are used for power distribution, then electrical connections can be established, but the size is large and contact resistance is high
Solution Approach 1:
The connector is divided into two separate halves that mate together, with each half containing a power bar. This segmentation allows for compact design while maintaining low contact resistance through direct metal-to-metal contact between the mating surfaces of the two halves.
Solution Approach 2:
The power bars are positioned in a planar configuration within the connector housing, utilizing two-dimensional space efficiently. The mating surfaces are designed to contact along an entire plane rather than at discrete points, reducing contact resistance while minimizing connector volume.
2Duration of action of moving object
If traditional power connectors are used, then electrical connections are established, but wear of contacts occurs rapidly
Solution Approach 1:
The contact interface is extended from point or line contact to surface-to-surface contact between the mating halves. This distributes the mechanical and electrical stress across a larger area, significantly reducing wear on individual contact points and extending connector lifespan.
Solution Approach 2:
The mating surfaces are designed with specific geometric parameters including flatness tolerances and contact pressure distribution. The surfaces are made substantially flat to ensure uniform contact across the entire interface, reducing stress concentration and minimizing wear during connection and disconnection cycles.
3Reliability
If traditional connectors are used, then power distribution is achieved, but connection quality is difficult to assess
Solution Approach 1:
The connector incorporates visual indicators such as colored markings or transparency features on the housing that change or become visible when proper connection is achieved. This allows operators to quickly assess connection quality without specialized equipment, ensuring reliable power distribution while simplifying quality verification.
4Volume of moving object
If rigid power distribution bars are connected using traditional methods, then electrical connections are established, but the connector size is large
Solution Approach 1:
The connector halves are designed with asymmetric features including positioning keys, shaped mounting surfaces, and non-uniform contact areas. This asymmetry provides inherent alignment guidance during assembly, ensuring precise positioning of the power bars while minimizing the overall connector volume through optimized spatial arrangement.
Data Source
AI summary
Electrical connector for supplying current to electronic circuits. The connector comprises a flat metal bar and an insulating case (12) having an open cavity (16) extended by an inclined support (18) covered by an end portion (20) of the bar.