U-Shaped Connector Adapter for Small Passive Component Integration
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Solution Overview
Problem
The existing connector systems face challenges in connecting smaller passive circuit devices, such as capacitors, due to the larger gap between conductor leads, which prevents smaller packages from electrically connecting, and this limits the density of conductor leads and signal speed, as well as the ability to separate traces for soldering.
Innovation Solution
A connector adapter with U-shaped conductors, where the longer legs are closer together and the shorter legs are farther apart, allowing smaller packages to span the gap between conductor leads, enabling electrical connection to larger gaps, and allowing multiple packages to be connected in parallel or series.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If smaller passive circuit devices are used, then device density and signal speed are improved, but the larger gap between conductor leads prevents electrical connection
Solution Approach 1:
The adapter serves as an intermediary component between the smaller passive circuit device and the connector with larger conductor lead gaps. The adapter includes a first contact that receives the smaller device and a second contact that connects to the connector, bridging the size mismatch and enabling electrical connection despite the gap discrepancy.
Solution Approach 2:
The adapter introduces an additional dimensional layer in the connection path. Instead of directly connecting the smaller device to the connector contacts, the adapter extends the connection in a different spatial dimension, allowing the device to be positioned closer to the first contact while the adapter bridge spans the gap to reach the second contact.
2Reliability
If larger capacitor packages are used, then electrical connection is ensured, but available space for placement is reduced
Solution Approach 1:
The connection system is segmented into three distinct components: the smaller passive circuit device, the adapter, and the connector. This segmentation allows the device to maintain its small size for space efficiency while the adapter handles the connection bridging function, separating the device size from the connection requirements.
Solution Approach 2:
The adapter acts as a mediator that decouples the device size from the connector contact spacing. By introducing this intermediate component, smaller devices can be used without compromising connection reliability, as the adapter compensates for the size mismatch rather than requiring the device itself to be large.
3Productivity
If conductor lead gap is reduced, then smaller packages can connect directly, but manufacturing precision requirements increase
Solution Approach 1:
The adapter serves as a buffer that absorbs the manufacturing tolerance variations. By introducing this intermediate component with its own contact spacing, the system relaxes the precision requirements for the connector conductor leads, as the adapter can accommodate larger gaps that are easier to manufacture.
Solution Approach 2:
The adapter changes the critical dimension parameter from the connector contact spacing to the adapter contact spacing. This parameter transformation allows the use of larger, more manufacturable gaps in the connector while the adapter handles the precise positioning for the smaller device connection.
Data Source
AI summary
An adapter has two conductors each with a U-shaped bend forming upper longer legs and lower shorter legs. The conductors face each other with the longer legs linearly aligned with each other and the shorter legs aligned with each other, thereby forming a first gap between the longer legs and a second gap between the shorter legs. The first gap is substantially smaller than the second gap, so that an electrical package can be placed across the first gap to contact the two upper longer legs, while the two shorter legs are spaced further apart to span a larger gap between conductors of a connector. Thus, the adapter enables the electrical package to be connected to conductors having a gap that is larger than the electrical package.