Wafer-Based Electrical Connector for Weight Reduction and Environmental Sealing
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Solution Overview
Problem
There is a need for a cost-effective and reliable electrical connector system that can provide weight reduction and/or space reduction, particularly in applications where environmental sealing is important, such as in military and aerospace industries.
Innovation Solution
An electrical connector design featuring a shell with a cavity housing a wafer assembly, where the wafers are arranged parallel and sealed by an interfacial seal with slots that receive the wafers, providing environmental sealing and allowing for flexible printed circuit boards to be connected, enabling customization and scalability for various applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cable connectors are used to establish electrical connections between backplane and daughter cards, then reliable electrical connections are achieved, but the system weight and space occupation increase significantly
Solution Approach 1:
The patent transitions from traditional three-dimensional cable-based connections to a two-dimensional wafer-based connection system. Multiple electrical contacts are arranged in parallel on a flat wafer substrate, allowing high-density connections without the bulk of cables. This dimensional reduction eliminates the need for heavy cable assemblies while maintaining reliable electrical connections between backplane and daughter cards.
Solution Approach 2:
The patent combines multiple electrical contacts, insulation structures, and sealing elements into a single integrated wafer assembly. The wafer housing consolidates what would traditionally require separate cable connectors, shields, and seals into one compact unit, significantly reducing overall system weight while maintaining connection reliability.
2Reliability
If traditional cable connectors are used to establish electrical connections, then electrical connectivity is achieved, but the system occupies a large amount of space
Solution Approach 1:
The patent transitions from traditional three-dimensional cable-based connections to a two-dimensional wafer-based connection system. Multiple electrical contacts are arranged in parallel on a flat wafer substrate, allowing high-density connections without the bulk of cables. This dimensional reduction eliminates the need for heavy cable assemblies while maintaining reliable electrical connections between backplane and daughter cards.
Solution Approach 2:
The wafer assembly is received within a cavity in the connector housing, with the wafer nested inside the protective housing structure. The mating connector similarly nests its wafer assembly within its own housing, creating a compact interconnected system that minimizes overall volume while maintaining connection integrity.
3Reliability
If wafers are extended from the front end of the housing for electrical mating, then electrical connectivity is improved, but environmental sealing becomes more difficult to achieve
Solution Approach 1:
The patent employs an elastomeric seal member that forms a flexible barrier between the wafer assembly and the external environment. This thin film seal conformally seals around the wafer edges and protrusions, preventing environmental contaminants from penetrating into the electrical connection interface while allowing the wafers to extend for mating.
Solution Approach 2:
The elastomeric seal member acts as an intermediary element between the electrical wafers and the external environment. It provides a protective barrier that isolates the sensitive electrical contacts from environmental factors while still permitting the wafers to extend beyond the housing for electrical mating with the connector.
4Object-affected harmful factors
If a seal is provided at the rear opening to seal the retainer, then environmental sealing is improved, but the complexity of the connector structure increases
Solution Approach 1:
The patent combines the sealing function with the existing rear wall structure of the connector housing. The elastomeric seal member is integrated into the housing cavity design, eliminating the need for separate complex sealing mechanisms. This consolidation maintains environmental sealing while reducing overall structural complexity.
Solution Approach 2:
The elastomeric seal member forms a flexible barrier between the wafer assembly and the external environment. This thin film seal conformally seals around the wafer edges and protrusions, preventing environmental contaminants from penetrating into the electrical connection interface while allowing the wafers to extend for mating.
Data Source
Figure 1
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AI summary
An electrical connector (304) includes a shell (410) having a cavity (412) and a wafer assembly (414) received in the cavity. The wafer assembly includes a wafer housing (426) holding a plurality of electrical wafers (420) configured to be electrically mated to a mating connector (302). The wafer housing has a front end (427) and the wafers extend forward from the front end being arranged parallel to each other within the cavity. Each wafer includes a first edge (424) and a second edge (424) with at least one trace (422) between the first and second edges. An interfacial seal (416) is provided along the front end. The interfacial seal is configured to seal between the electrical connector and the mating connector. The interfacial seal provides an environmental seal for the wafer assembly.