Socket Member Electrical Connector Withstand Harsh Environments
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Solution Overview
Problem
Conventional electrical connectors are inadequate for maintaining reliable connections in harsh environments with extreme temperatures and constant shock or vibrations, such as aerospace or military applications.
Innovation Solution
The electrical connector assembly features a sub-assembly with socket members and twist pin contacts that form a mechanical and electrical connection, housed in shields to withstand vibrations and shock, while maintaining high-speed signal transmission and integrity, adhering to military specifications like MIL-DTL-83513.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical connectors are used in harsh environments, then the connector structure remains simple, but the reliability of electrical connection deteriorates under extreme temperatures and vibrations
Solution Approach 1:
The connector is divided into multiple independent components including a housing, contact members, socket members, and shielding structures. Each component performs a specific function and can be manufactured separately, then assembled to form the complete connector assembly capable of withstanding harsh environments
Solution Approach 2:
The socket members are inserted into cavities within the housing structure, and contact members are positioned within the housing as well. The shielding structures envelop the contact members, creating a nested arrangement that protects internal components while maintaining compact overall dimensions
Solution Approach 3:
The connector design incorporates features that preemptively address harsh environment challenges through robust mechanical construction, precise alignment mechanisms, and protective shielding that are built into the structure before deployment, ensuring reliability without requiring complex active compensation systems
2Reliability
If the connector is designed to withstand extreme conditions, then the reliability improves, but the manufacturing complexity increases
Solution Approach 1:
Dividing the connector into modular components enables each part to be manufactured using optimized processes for its specific requirements, then assembled through standardized interfaces, improving both reliability and manufacturability
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it provides mechanical support, defines cavity positions for socket members, offers mounting surfaces for contact members, and integrates shielding structures. This multi-functionality reduces the number of separate components needed
3Reliability
If socket members are inserted into cavities to form connections, then electrical coupling is achieved, but the connector complexity increases compared to conventional designs
Solution Approach 1:
Socket members are inserted into cavities formed within the housing structure, creating a nested arrangement where the socket member shafts extend through the housing front face while their bases are received and retained within the cavity spaces, achieving stable electrical coupling through this integrated nested configuration
Solution Approach 2:
The housing structure combines multiple functions: it provides the structural framework, contains the cavities for socket members, supports the contact members, and integrates the shielding structures. This merging of functions into a single housing component reduces overall assembly complexity
Data Source
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AI summary
An electrical connector (108) is provided and includes a housing that has a mating face configured to engage a mating connector (116). The electrical connector (108) also includes a plurality of conductors that extend through the housing and a plurality of socket members (130) that project from the mating face. Each socket member (130) is electrically coupled to one of the conductors and includes a shaft that is configured to be inserted into a cavity of the mating connector (116). The shaft forms a passage that is configured to receive an associated mating contact held within the cavity for establishing an electrical connection.