High Speed Data Module Vertical Insert Alignment
Solution Overview
Problem
Existing high-speed data contact systems are not adapted for high life-cycle or mass interconnect devices that require thousands or tens of thousands of connection cycles, lacking the necessary durability and alignment features.
Innovation Solution
A vertical insert for high-speed data modules with a multi-stage lead-in housing and controlled float mechanism for pre-alignment of contacts, featuring protective arms with beveled edges, latches, and keying members to ensure proper orientation and extended cycle life, along with direct welding of contacts for optimal electrical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If conventional high-speed data contact systems are used, then basic data transmission function is achieved, but cycle life is insufficient for high life-cycle applications requiring thousands or tens of thousands of connection cycles
Solution Approach 1:
The insert includes a multi-stage lead-in housing with controlled float that performs preliminary alignment of contacts before engagement. This pre-alignment action ensures proper positioning of male and female contacts prior to connection, reducing stress during mating and extending cycle life for high life-cycle applications
Solution Approach 2:
The contact system is divided into separate insert and receiver components that can be independently manufactured and assembled. The insert contains multiple contacts organized in stages, allowing for modular replacement and maintenance while extending overall system cycle life
2Manufacturing precision
If existing high-speed data contact systems are used, then data transmission is enabled, but alignment precision is insufficient for reliable engagement in mass interconnect devices
Solution Approach 1:
The multi-stage lead-in housing performs preliminary alignment of contacts before final engagement. This staged approach guides male and female contacts into proper alignment progressively, ensuring manufacturing precision is achieved while maintaining ease of operation through self-aligning features
Solution Approach 2:
The controlled float mechanism acts as an intermediary between the insert housing and the contact tips. It provides a compliant interface that absorbs misalignment errors while maintaining precise contact alignment, bridging the gap between manufacturing tolerances and operational requirements
3Reliability
If conventional contact systems are used, then basic connectivity is achieved, but durability for thousands or tens of thousands of connection cycles is not attained
Solution Approach 1:
The controlled float mechanism performs preliminary stress distribution during engagement. By distributing forces progressively through multiple contact stages, it reduces peak stresses on individual contacts, extending durability without requiring overly complex structural reinforcements
Solution Approach 2:
The housing and contact support structures are merged into integrated components. The lead-in housing simultaneously provides mechanical support, alignment guidance, and stress distribution functions, achieving high durability while controlling overall structural complexity through functional integration
Data Source
AI summary
A vertical insert and pass-thru for high speed contact sets or modules for use with high life-cycle or mass interconnect devices.