Universal Power Connector Contacts for Simplified Assembly

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Solution Overview

Problem

The existing connector systems for transmitting electrical power require two different types of power contacts for header and receptacle connectors, leading to increased manufacturing costs, complexity, and potential human errors due to the need for separate tooling and assembly processes.

Innovation Solution

The use of identical power contacts in both header and receptacle connectors, featuring a first and second plate-like body member with alternating straight and angled contact beams, which mate securely to establish electrical and mechanical contact, reducing the need for dual tooling and simplifying assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If two different types of power contacts are used for header and receptacle connectors, then the connectors can establish electrical and mechanical contact, but the manufacturing cost and device complexity increase due to the need for separate tooling and assembly processes

Engineering Contradiction:

Improveelectrical and mechanical contactVSAvoiddual tooling requirements

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The power contact is designed with universal functionality to serve both header and receptacle connector roles. By incorporating complementary mating features (straight contact beams and angled contact beams) within the same power contact design, a single universal power contact can be used in both connector types, eliminating the need for separate tooling and reducing manufacturing complexity while maintaining reliable electrical and mechanical contact.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If two different types of power contacts are used for header and receptacle connectors, then the connectors can establish electrical and mechanical contact, but assembly costs increase due to different processes and machinery requirements

Engineering Contradiction:

Improveelectrical and mechanical contactVSAvoidassembly process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The power contact design integrates both header and receptacle functionality into a single universal component. The complementary mating features (straight contact beams for one connector type, angled contact beams for the other) are incorporated within the same power contact structure, allowing identical assembly processes and machinery to be used for both connector types, thereby reducing assembly costs and simplifying manufacturing.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If two different types of power contacts are used for header and receptacle connectors, then the connectors can establish electrical and mechanical contact, but the parts count and inventory requirements increase

Engineering Contradiction:

Improveelectrical and mechanical contactVSAvoidparts count

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The power contact is designed as a universal component that can be used in both header and receptacle connectors. By incorporating complementary mating features within the same power contact design, the parts count is reduced since only one type of power contact needs to be manufactured and inventoried, rather than maintaining separate stock of two different types, while still ensuring reliable electrical and mechanical contact.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS7425145B2Connectors and contacts for transmitting electrical power

Publication Date: 2008.09.16 FCI AMERICAS TECHNOLOGY LLC

AI summary

A connector system includes a first connector, and a second connector that mates with the first connector. The same type of power contact is used in the first and second connectors.