U-Shaped Connector Contact Layout for Compact Precise Mating
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Solution Overview
Problem
Existing electrical connectors lack efficient design for reduced dimensionality and flexible contact alignment during mating, leading to potential misalignment and increased connector size.
Innovation Solution
The electrical connector features a U-shaped contact structure with a stationary inner arm, a flexible outer arm, and a soldering portion connected to a bottom arm, allowing for staggered soldering portion placement and alignment, which reduces the connector's dimension in one direction and facilitates smooth mating with a complementary connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional contact structures are used, then manufacturing is simpler, but connector size increases and mating precision decreases
Solution Approach 1:
The contact is divided into multiple functional segments: an inner arm portion, an outer arm portion, and a bottom arm portion. Each segment serves a specific function - the inner arm provides stable alignment, the outer arm enables flexible engagement, and the bottom arm facilitates soldering. This segmentation allows the connector to achieve compact dimensions while maintaining high mating precision through the coordinated action of these specialized segments.
Solution Approach 2:
The contact structure utilizes three-dimensional spatial arrangement with arms extending in multiple directions (inner arm in one direction, outer arm in another direction, bottom arm connecting them). This multi-dimensional configuration allows the soldering portion to be positioned away from the mating interface area, reducing the connector's footprint in the critical mating dimension while preserving manufacturing accessibility and mating precision.
2Ease of operation
If contacts are made flexible for better alignment, then mating efficiency improves, but structural integrity may compromise
Solution Approach 1:
Different portions of the contact exhibit different mechanical properties tailored to their specific functions. The inner arm is designed with higher rigidity to provide stable alignment and maintain structural integrity during soldering. The outer arm incorporates flexibility to enable smooth engagement and accommodate misalignment during mating. This localized differentiation of mechanical properties allows the contact to achieve both mating efficiency and structural integrity simultaneously.
Solution Approach 2:
The contact structure transitions from a static, uniformly rigid design to a dynamic system where different portions can move independently. The outer arm is designed to flex during the mating process to guide alignment, while the inner arm remains relatively stable. This dynamic behavior enables the contact to adapt to variations in assembly tolerance, improving mating efficiency without compromising the overall structural integrity of the connector.
Data Source
AI summary
An electrical connector includes an insulative housing defining a channel and plural contacts secured to the insulative housing, each contact having a first arm exposed to the channel, a second arm exposed to the channel, a bottom arm connected to the first and second arms, and a soldering portion connected to the bottom arm.