Ruggedized Electrical Connector Sealing and Grounding
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Solution Overview
Problem
Existing electrical connectors, such as USB connectors, are limited by their size and lack of robustness, which hinders the design of newer devices and fails to meet the increasing demands for smaller, thinner, and more powerful connectors capable of withstanding extreme environments.
Innovation Solution
A ruggedized electrical connector with a conductive shell and sealing members that provides a ground path and improved sealing to prevent contaminants, featuring a contact subassembly with interface and tail ends, and a unique footprint on the printed circuit board to enhance electrical properties like impedance and crosstalk performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If existing USB connectors are used, then basic electrical connection is achieved, but size and volume are too large for newer device designs
Solution Approach 1:
The connector is divided into distinct functional segments: a shell for structural support and grounding, a contact subassembly with multiple contacts arranged in a matrix, and separate sealing members. This segmentation allows optimization of each component's function while reducing overall volume.
Solution Approach 2:
The contact subassembly is nested within the shell, with contacts arranged in a compact matrix pattern. The internal sealing member is nested within the contact subassembly housing, creating a space-efficient nested structure that minimizes volume while maintaining functionality.
2Reliability
If existing USB connectors are used, then basic connectivity is provided, but they lack the robustness to withstand extreme environments
Solution Approach 1:
Different regions of the connector have specialized properties: the shell provides structural strength and grounding, the contact subassembly ensures reliable electrical connection, and the sealing members provide environmental protection. Each component is optimized for its specific function, achieving high robustness without unnecessary overall complexity.
Solution Approach 2:
The connector combines multiple materials with complementary properties: conductive materials for the shell and contacts, insulating materials for the contact subassembly housing, and elastomeric materials for the sealing members. This composite approach enhances environmental robustness while managing structural complexity.
3Volume of moving object
If connector size is reduced, then device integration is improved, but sealing and contamination protection become more difficult
Solution Approach 1:
The sealing members are made of elastomeric material that can deform to seal around the contacts and internal components. This flexible sealing approach effectively prevents contaminant ingress while accommodating the compact connector size and allowing for thermal expansion and contraction.
Solution Approach 2:
The interface sealing member is positioned at the front interface before contaminants can enter, and the internal sealing member is positioned within the contact subassembly housing to prevent internal contamination. These preliminary sealing actions block contaminant paths before they can reach sensitive internal components.
4Quantity of substance
If more contacts are packed into smaller space, then connectivity options increase, but electrical properties like impedance and crosstalk worsen
Solution Approach 1:
The contacts are arranged in a two-dimensional matrix pattern rather than a linear arrangement, allowing more contacts to be packed into a smaller footprint area. This dimensional change enables increased connectivity options while maintaining adequate spacing between contacts to control impedance and minimize crosstalk.
Solution Approach 2:
The contact subassembly housing provides localized insulation and positioning for each contact, ensuring precise electrical property control. The housing material and structure are specifically designed to maintain consistent impedance and minimize crosstalk between adjacent contacts in the dense matrix arrangement.
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 ruggedized connector minimizes size and weight while ensuring durability and safety, enabling its use in portable devices and improving electrical performance by preventing contamination and providing a reliable ground path.
Implementation Method 1
A conductive shell having an interface front side and an opposite rear side. The conductive shell provides a ground path to the printed circuit board.
Implementation Method 2
An interface sealing member is coupled to the interface front side of the shell. The interface sealing member substantially covers the interface front side of the shell for preventing contaminants from passing externally around the shell.
Implementation Method 3
An internal sealing member is coupled around the housing for preventing contaminants from passing internally though the shell.
Data Source
AI summary
A ruggedized electrical connector that includes a shell that has an interface front side and an opposite rear side for mounting on a printed circuit board. An interface sealing member is coupled to the interface front side of the shell. The interface sealing member substantially covers the interface front side of the shell for preventing contaminants from passing externally around the shell. A contact subassembly is received in the shell and includes a plurality of contacts and a housing supporting the contacts. Each of the contacts has an interface end and a tail end. The interface ends are arranged in a mating platform extending from the housing toward the front side of said shell for engaging a mating connector. An internal sealing member is coupled around the housing for preventing contaminants from passing internally though the shell. A rear shield is coupled to the rear side of the housing.