Spring-Loaded Electrical Connector for Reliable High-Density Mating
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Solution Overview
Problem
Conventional high density electrical connectors face issues with contact intermittency, mating reliability, and increased cost due to tight pitch and density, leading to tolerance stack-up and connectivity failures.
Innovation Solution
A spring-loaded core design with a contact carrier and interposer system that allows for axial sliding between unmated and mated positions, ensuring consistent signal integrity and alignment, while maintaining a compact size and high contact density.
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 connector size is reduced, but contact intermittency and mating reliability deteriorate due to tolerance stack-up
Solution Approach 1:
The core is made axially slidable within the housing, transitioning from a static to a dynamic structure. This allows the core to move and compensate for tolerance variations during mating, ensuring reliable contact despite tight pitch and high density constraints.
Solution Approach 2:
The spring member changes the axial position parameter of the core dynamically. By adjusting the core's position through spring force, the system compensates for tolerance stack-up and maintains consistent contact pressure and signal integrity.
2Quantity of substance
If high density contacts are implemented, then signal count increases, but manufacturing cost increases
Solution Approach 1:
The slidable core mechanism serves multiple functions: it maintains contact pressure, compensates for tolerance variations, and ensures consistent signal integrity across all contacts. This single mechanism addresses multiple reliability issues simultaneously, reducing the need for additional expensive manufacturing processes.
3Volume of moving object
If tight pitch is used to achieve high density, then connector compactness improves, but contact intermittency increases due to tolerance stack-up
Solution Approach 1:
The axially slidable core transforms the static contact structure into a dynamic one that can adapt to tolerance variations. The core moves to maintain optimal contact pressure, eliminating intermittency issues caused by tight pitch constraints.
Solution Approach 2:
The spring member dynamically adjusts the axial position of the core, changing the contact pressure parameter to compensate for tolerance stack-up. This ensures consistent electrical contact despite the compact dimensions required for high density.
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 design provides reliable, high-density electrical connections with consistent signal integrity, allowing up to 5,000 cycles of mating and unmating, and reduces manufacturing costs by maintaining connector size and signal count.
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.