Segmented Electrical Connector Shell for Blind Mating Alignment
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Solution Overview
Problem
Miniaturized electrical connectors are susceptible to damage from misalignment and misorientation during mating operations, leading to signal and power transmission failures due to improper force application on fragile internal elements.
Innovation Solution
The electrical connector is designed with segments of varying widths and heights, featuring locking and latching mechanisms to ensure proper alignment and secure fixation, minimizing misalignment and improper force application during blind mating.
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 structural integrity and susceptibility to damage during handling and mating operations deteriorate
Solution Approach 1:
The connector is divided into multiple segments with different widths, creating a multi-section structure that provides both compactness and structural reinforcement. The segmentation allows different portions of the connector to serve different functions while maintaining overall structural integrity despite miniaturization
Solution Approach 2:
Different segments of the connector are designed with different widths to provide localized structural properties. The varying width segments create areas of different stiffness and strength, allowing the connector to be both compact and resistant to damage during handling and mating operations
2Weight of stationary object
If connectors are made thinner and lighter for portable electronics, then portability is improved, but resistance to damage from misalignment and misorientation during mating deteriorates
Solution Approach 1:
The connector employs asymmetric design with segments of different widths rather than a uniform cylindrical shape. This asymmetry provides geometric cues that guide proper alignment during mating operations, reducing the likelihood of misalignment or misorientation that could damage the thinner, lighter connector structure
Solution Approach 2:
The varying width segments are designed to guide the mating process in advance, creating a self-aligning mechanism that prevents misalignment before it can cause damage. The geometric features prepare the connector for proper engagement before the actual mating force is applied
3Ease of operation
If blind mating is performed without visual observation, then ease of operation is improved, but risk of misorientation and misalignment leading to internal element damage increases
Solution Approach 1:
The asymmetric varying width segment design provides tactile and geometric guidance that enables blind mating without visual observation. The unique width pattern acts as a geometric code that guides proper orientation and alignment, allowing operators to mate connectors confidently without seeing the connection point
Solution Approach 2:
The connector's varying width segments create a self-aligning mechanism that automatically guides proper mating without external visual assistance. The geometric features perform the alignment function that would otherwise require visual observation, allowing the connector to guide itself into correct position during blind mating operations
Data Source
AI summary
An electrical connector includes an insulative housing, metal terminals, and a shell surrounding the housing. Contact portions of the metal 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 includes a first portion having a first length and a first width, and a second portion having a second length and a second width different from the first width. The first and second portions of the shell may have heights that are different from each other, such that a step is positioned between the first and second portions of the shell. The housing may have first and second portions having different heights, such that a shoulder is positioned between the first and second portions of the housing.