CASE STUDY FOUR - BESPOKE DOCKING CONNECTOR SYSTEM
This system encompasses two mating connectors that are used in "docking" conditions; one half is contained in the main terminal and the other with the cradle.
The main terminal connector is a complex, innovative design that incorporates both the signal and power contacts within a small footprint. The geometry of the contacts was designed using stress analysis and material evaluation processes to ensure that a reliable design resulted, and utilises stamped contacts, and two insert moulding process stages.
The cradle connector packages custom sprung loaded "POGO" contacts to mate with the main terminal connector when the terminal is dropped into the cradle.
This connector also takes advantage of insert moulding the contacts to give a reliable interconnect system. It is therefore possible to manufacture a cost reduced, partially loaded connector to suit alternative application, whilst maintaining the water resistance properties.
Both connectors are water resistant to IP67 and withstand a high number of mating cycles.
See other Case Studies:
Case Study One - Cable Assembly
Case Study Two - Bespoke Connector System
Case Study Three - CF (Compact Flash) Card Kit