Ring-Segment Electrical Connector for High-Density Contact Alignment
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Solution Overview
Problem
Conventional high-density electrical connectors face challenges in aligning multiple groupings of electrical contacts predictably and efficiently due to unpredictable primary datum issues, leading to misalignment and unreliable connections.
Innovation Solution
The design incorporates a plug and receptacle with arc-shaped apertures and ring-segment assemblies, allowing for flexible electrical contacts that can move radially while being constrained laterally, ensuring proper alignment and contact through a plug frame with concentric rings and spokes, enabling independent assembly of ring-segment assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional stacked electrical contact boards are used, then high-density electrical connections can be achieved, but misalignment and unreliable connections occur due to unpredictable primary datum issues
Solution Approach 1:
The electrical connector is divided into multiple independent ring-segment assemblies, each containing a subset of electrical contacts. These segments are circumferentially spaced and can be independently positioned and assembled, eliminating the need for complex stacked board alignment. Each ring-segment assembly acts as an independent modular unit that simplifies the overall alignment process while maintaining high contact density.
Solution Approach 2:
A frame structure with arc-shaped apertures serves as an intermediary component that precisely positions and holds multiple ring-segment assemblies. The frame acts as a primary datum reference, providing predetermined alignment features that ensure accurate positioning of electrical contacts without relying on unpredictable board-to-board alignment. This intermediary structure mediates between the individual contact segments and the overall connector assembly.
2Reliability
If multiple groupings of electrical contacts are aligned predictably, then reliable connections are achieved, but manufacturing and assembly complexity increases
Solution Approach 1:
The connector is segmented into independent ring-segment assemblies that can be manufactured and pre-assembled separately. Each segment contains a manageable number of electrical contacts arranged in an arc, making individual assembly straightforward. These pre-assembled segments are then simply positioned circumferentially around the frame, dramatically simplifying the overall assembly process compared to traditional stacked board methods while ensuring reliable connections through predetermined alignment features.
Solution Approach 2:
The frame structure is designed with predetermined alignment features and arc-shaped apertures that guide the positioning of ring-segment assemblies before final assembly. Electrical contacts within each ring-segment are pre-positioned and secured in their respective apertures. This preliminary preparation of alignment features and pre-assembly of segments ensures reliable connections are achieved without requiring complex alignment procedures during final assembly.
3Reliability
If electrical contacts are allowed to flex radially for alignment compensation, then connection reliability improves, but structural stability decreases
Solution Approach 1:
The electrical contacts are organized into discrete ring-segment assemblies rather than continuous stacked boards. This segmentation allows each ring-segment to flex independently radially to compensate for alignment variations during insertion, while the overall structural integrity is maintained by the rigid frame that holds the segments in their predetermined circumferential positions. The segmentation isolates flexing movements to local segments without compromising global structural stability.
Solution Approach 2:
The frame structure provides rigid structural support and predetermined alignment at the global level, while the ring-segment assemblies are designed with localized flexibility to allow radial movement of electrical contacts. This creates a hierarchy where the frame maintains overall structural stability and positioning, while individual ring-segments provide local flexibility for alignment compensation. Each component has optimized properties suited to its specific function.
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 configuration ensures reliable and efficient high-density electrical connections by maintaining proper alignment and electrical isolation, facilitating easy assembly and reducing manufacturing complexity.
Implementation Method 1
One of a first end of each one of the at least some of the plug electrical contacts is allowed to flex radially in an inward radial direction with respect to a second end of the corresponding one of the at least some of the plug electrical contacts
Data Source
AI summary
An electrical connector. The electrical connector includes a plug. The plug includes a plug frame and plug ring-segment assemblies. The plug frame includes plug apertures. Each one of the plug ring-segment assemblies includes a plug ring-segment and a plurality of plug electrical contacts. The electrical connector further includes a receptacle. The receptacle includes a receptacle frame and receptacle ring-segment assemblies. The receptacle frame includes receptacle apertures. Each of the receptacle ring-segment assemblies includes a receptacle ring-segment and a plurality of receptacle electrical contacts. The plug is selectively connectable with the receptacle. When the plug is selectively connected to the receptacle, each one of at least some of the plug electrical contacts is in physical contact with a corresponding one of the receptacle electrical contacts.