Staggered Contact Electrical Connector for Reduced Mating Force
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Solution Overview
Problem
Conventional electrical connectors face challenges in alignment and mating due to increased contact density, requiring higher mating forces and often using cumbersome thumb screws for securement, which are difficult to tighten and loosen.
Innovation Solution
The connector design features a matrix of contact cavities with contacts at staggered depths, utilizing blind mating members and locking mechanisms to facilitate easy alignment and reduced mating forces, with staggered contact placement to ease engagement and secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If more contacts are housed in each connector to accommodate higher power demands, then the power transmission capability is improved, but the mating force required to fully mate the connectors is increased
Solution Approach 1:
The contacts are divided into two depth groups: first depth contacts and second depth contacts. This segmentation allows the mating process to occur in stages, with shallower contacts engaging first and deeper contacts engaging second, thereby distributing the mating force over time and reducing the peak force required
Solution Approach 2:
The patent introduces a depth dimension variation among contacts within the same connector. By positioning contacts at different depths (first depth vs. second depth), the patent creates a staggered engagement sequence that reduces mating force requirements while maintaining high contact density for power transmission
2Reliability
If connectors require alignment and proper orientation for mating, then the connection reliability is improved, but the ease of operation is worsened due to limited visibility and accessibility
Solution Approach 1:
The connector housing includes alignment features such as guide pins, alignment ribs, or positioning protrusions that automatically align the plug and receptacle connectors before the contacts engage. This preliminary alignment action ensures proper orientation without requiring the user to manually align the connectors, thereby maintaining connection reliability while improving ease of operation
3Stability of the object's composition
If thumb screws are used to secure the connectors, then the connection stability is improved, but the ease of operation is worsened due to difficulty in tightening and un-tightening
Solution Approach 1:
The patent replaces the manual thumb screw mechanical system with an automatic locking mechanism. This locking mechanism may include spring-loaded latches, snap-fit features, or cam-actuated locks that automatically engage when the connectors are mated, providing secure connection stability without requiring the user to manually tighten or loosen screws
Data Source
AI summary
A connector includes a housing with a plurality of contact cavities arranged in a matrix having M columns and N rows of contact cavities. Each of the contact cavities extend between a contact loading side and a mating side of the housing. Contacts are received within respective ones of the contact cavities, wherein a first group of the contacts are held within the contact cavities at a first depth with respect to the contact loading side and a second group of the contacts are held within the contact cavities at a different second depth with respect to the contact loading side.