Spring-Loaded Electrical Connector for High-Density Mating Alignment
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Solution Overview
Problem
Conventional high density electrical connectors face issues with contact intermittency, mating reliability, and increased manufacturing costs due to tight pitch and density, leading to tolerance stack-up related connectivity failures and bulkiness.
Innovation Solution
A spring-loaded electrical connector design featuring a core slidably coupled to a housing, with a spring member and interposer, allowing axial movement between unmated and mated positions, ensuring consistent signal integrity and alignment through alignment pins and latching mechanisms, while maintaining high density and compact size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If tight pitch and high density are used to achieve small package size, then the connector size is reduced, but contact intermittency and mating reliability deteriorate due to tolerance stack-up
Solution Approach 1:
The core is made slidable within the housing along the longitudinal axis, transforming from a static to a dynamic structure. This allows the core to move axially between unmated and mated positions, accommodating tolerance variations while maintaining reliable contact in high-density configurations
Solution Approach 2:
The spring member changes the positional parameter of the core by applying elastic force. The core's position varies dynamically based on mating state, with the spring providing the necessary force to overcome tolerance stack-up and ensure consistent electrical contact
2Volume of moving object
If tight pitch and high density are used to achieve small package size, then the connector size is reduced, but contact intermittency increases due to tolerance stack-up
Solution Approach 1:
The slidable core design allows dynamic adjustment of contact positions during mating, compensating for manufacturing tolerances in high-density arrangements where fixed precision is difficult to achieve
Solution Approach 2:
The spring member provides pre-compression force that cushions against tolerance variations before contact is made, ensuring reliable electrical connection despite manufacturing imprecisions inherent in tight-pitch designs
3Quantity of substance
If increased signal count is accommodated, then connectivity capability is improved, but connector size increases due to bulkiness
Solution Approach 1:
The slidable core mechanism adds a temporal/dynamic dimension to the connector design, allowing high signal density to be achieved without proportional size increase by utilizing axial movement rather than expanding lateral dimensions
4Quantity of substance
If conventional high density design is used, then signal count is increased, but manufacturing cost increases
Solution Approach 1:
The slidable core with spring member serves multiple functions: maintaining contact pressure, accommodating tolerances, and enabling high-density packing. This multi-functional design achieves high signal count without proportionally increasing manufacturing complexity or cost
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 connector provides stable, reliable electrical connections with consistent signal integrity, supports high density contacts, and allows for increased signal count without increasing size, with a durable design capable of 5,000 mating cycles, and includes features for fine alignment and latching to secure connections.
Implementation Method 1
A spring member is received inside of the housing and behind the core for abutment with the spring engagement end of the core. The core is axially slidable with respect to the inner support member along a longitudinal axis of the housing between an unmated position, in which the spring member pushes the core outwardly away from the cable termination end of the housing
Data Source
AI summary
Electrical connectors and assemblies may include a housing and a contact member therein. The contact member includes electrical contacts. A contact barrier is connected to the housing and movable between a closed state and an open state. In the open state, the contact member is exposed and, in the closed state, the contact member is protected by the contact barrier. The contact barrier is biased into the closed state. Electrical connectors and assemblies may include a housing with a core assembly having at least one electrical contact. A rotatable coupling member is rotatably attached to an end of the housing and includes a coupling housing, at least one latching element coupled to an inner surface of the coupling housing, and at least one center biasing element configured to bias and self-center the rotatable coupling member relative to the housing into a ready-to-connect orientation.