Thin Electrical Connector with Lever-Actuated Contact
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Solution Overview
Problem
Conventional electrical connectors with a hook-shaped locking mechanism require a wider housing thickness to accommodate the upper beam's movement, leading to a larger connector size, and there is a need for a variety of types in the industry.
Innovation Solution
The electrical connector features a first contact element with a reduced upper beam movement range and a second contact element with a pendent support structure, where the moving portion locks with the actuator, allowing the second leg portion to move downward, reducing the connector's thickness and enabling a staggered contact array for secure gripping of the ribbon-shaped element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hook-shaped locking mechanism with wide upper beam movement range is used, then the locking strength is enhanced, but the housing thickness increases
Solution Approach 1:
The patent transitions from a single-dimension horizontal locking mechanism to a two-dimension mechanism that incorporates vertical movement. The upper beam moves both horizontally and vertically, with the locking portion engaging a locking hole that has both horizontal and vertical dimensions, allowing effective locking with reduced horizontal movement range and thus reduced housing thickness
Solution Approach 2:
The locking mechanism uses dynamic movement where the upper beam transitions from a horizontal movement-dominated state to a vertical movement state during the locking process. This dynamic transition allows the beam to achieve secure locking through vertical engagement while minimizing the horizontal space required, thereby reducing housing thickness without compromising locking strength
2Length of stationary object
If the upper beam movement range is reduced, then the housing thickness is reduced, but the locking strength may be compromised
Solution Approach 1:
By introducing vertical movement dimension to the locking mechanism, the patent compensates for the reduced horizontal movement range. The locking portion engages a locking hole that extends vertically, allowing the beam to achieve secure locking through vertical engagement while minimizing horizontal space requirements
Solution Approach 2:
The moving portion is positioned in advance to engage with the locking hole at an optimal position before the upper beam completes its movement. This preliminary engagement ensures that the locking action is effective even with a limited movement range, maintaining locking strength while allowing for a thinner housing
3Reliability
If two types of contact elements are used with different beam structures, then the ribbon-shaped element can be gripped securely, but the device complexity increases
Solution Approach 1:
The contact elements are segmented into first and second types with distinct structural characteristics. The first contact element uses a simple cantilever structure for basic contact, while the second contact element incorporates a rod-shaped beam with pendent support for enhanced gripping. This segmentation allows each element to be optimized for its specific function, achieving reliable gripping without requiring all elements to be overly complex
Solution Approach 2:
Different structural qualities are applied to different contact elements based on their specific functional requirements. The first contact element has a simpler structure suitable for general contact, while the second contact element has a more complex rod-shaped beam structure with pendent support specifically where needed for secure gripping of the ribbon-shaped element, optimizing the overall system without unnecessary complexity throughout
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
This design reduces the connector's thickness, enhances locking strength, minimizes ribbon bending, and shortens insertion distance, reducing abrasion and allowing for a more compact and versatile electrical connector.
Implementation Method 1
a reactive force against the pressing force causes the shaft portion to move upward
Implementation Method 2
the terminal end portion of the second leg portion moves downward due to the upward movement of the shaft portion
Data Source
AI summary
A novel electrical connector that is thin and can hold a belt-like body. The electrical connector has two kinds of contact elements. When an actuator is rotated, an operation section of the actuator presses one connector element downward, and force from the one connector element causes the rotation shaft of the actuator to move upward. As a result, a portion near one end of a bar-like section, supported in air, of the other contact element is elastically deformed upward. By the principle of leverage, a portion near the other end of a bar-like section of the other contact element is moved downward.