Staged Mating Electrical Connector Reduces Peak Insertion Force

Solution Overview

Problem

As electronic systems become more complex and require more interconnections, the increased number of mating terminals in electrical connectors leads to higher mating forces, which can exceed maximum requirements, making it difficult to easily connect and assemble components.

Innovation Solution

The electrical connector is designed with two housings that are connected in a slidable manner and feature a latch mechanism, allowing for a staggered mating sequence that reduces the required insertion force by engaging only half of the terminals at a time, effectively splitting the peak mating force into two separate events.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the number of mating terminals in electrical connectors is increased to meet complex system interconnection requirements, then the system's interconnection capability is improved, but the mating force required to fully engage corresponding connector pairs increases and may exceed maximum mating force requirements

Engineering Contradiction:

Improveinterconnection capabilityVSAvoidmating force

Core Design Contradiction:

Adaptability or versatilityVSForce

Solution Approach 1:

The connector housing is divided into two separate housings that can move relative to each other in stages. The first housing engages with the mating connector first, then the second housing engages subsequently. This segmentation allows the total mating force to be distributed across two separate engagement events rather than one, reducing the peak mating force required at any given time.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second housing is designed to be movable relative to the first housing in the insertion direction, creating a dynamic, two-stage engagement process. A latch mechanism selectively fixes the housings in a staggered position during engagement, allowing controlled sequential mating. This dynamic approach enables the connector to adapt the engagement process to maintain force requirements within acceptable limits.

Inventive Principle:

Principle #15Dynamics

2Power

If larger terminals are used to increase power handling requirements, then the power handling capability is improved, but the mating force required to engage the connector increases

Engineering Contradiction:

Improvepower handling capabilityVSAvoidmating force

Core Design Contradiction:

PowerVSForce

Solution Approach 1:

The connector housing is divided into two separate housings that can move relative to each other in stages. The first housing engages with the mating connector first, then the second housing engages subsequently. This segmentation allows the total mating force to be distributed across two separate engagement events rather than one, reducing the peak mating force required at any given time.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second housing is designed to be movable relative to the first housing in the insertion direction, creating a dynamic, two-stage engagement process. A latch mechanism selectively fixes the housings in a staggered position during engagement, allowing controlled sequential mating. This dynamic approach enables the connector to adapt the engagement process to maintain force requirements within acceptable limits.

Inventive Principle:

Principle #15Dynamics

3Reliability

If built-in terminal protection features are added to connectors, then the reliability and protection of terminals is improved, but the mating force required to engage the connector increases

Engineering Contradiction:

Improveterminal protectionVSAvoidmating force

Core Design Contradiction:

ReliabilityVSForce

Solution Approach 1:

The connector housing is divided into two separate housings that can move relative to each other in stages. The first housing engages with the mating connector first, then the second housing engages subsequently. This segmentation allows the total mating force to be distributed across two separate engagement events rather than one, reducing the peak mating force required at any given time.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second housing is designed to be movable relative to the first housing in the insertion direction, creating a dynamic, two-stage engagement process. A latch mechanism selectively fixes the housings in a staggered position during engagement, allowing controlled sequential mating. This dynamic approach enables the connector to adapt the engagement process to maintain force requirements within acceptable limits.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20230086860A1Staged Mating Electrical Connector

Publication Date: 2023.03.23 TE CONNECTIVITY GERMANY GMBH

AI summary

A connector comprises a first housing and a second housing each receiving a plurality of electrical terminals. The second housing is connected to the first housing, and is movable relative thereto in an insertion direction of the connector with respect to a mating connector. A latch selectively fixes the first housing in a staggered position relative to the second housing in the insertion direction.