Board-to-board connector plugging simulation evaluation method

Abstract

The invention provides a board-to-board connector plugging simulation evaluation method. The method comprises the following steps: step 1, generating a parameterized CAD (Computer Aided Design) model and a CAE (Computer Aided Engineering) model; 2, a contact area and a non-contact area in the CAD model and the CAE model are distinguished; 3, simulating the matching process of the male terminal and the female terminal, and completing the optimal design of the contact structure of the male terminal and the female terminal; 4, selecting a first evaluation target parameter; 5, an overall finite element simulation model used for floating simulation is established, and floating characteristics of the overall finite element simulation model are analyzed; 6, dividing the floating characteristics into offset type floating and torsion type floating, and simulating the change distribution of the positive contact pressure of the male terminal and the female terminal under the limit floating condition; according to the method, parametric modeling is carried out by adopting an APDL language, the transient dynamic finite element model is established, and the contact stability and durability of the connector are improved by optimizing the shape and the floating structure of the terminal contact.

Description

Technical Field

[0001] This invention relates to the field of connector technology, specifically to a simulation evaluation method for board-to-board connector insertion and removal. Background Technology

[0002] As electronic devices evolve towards higher density, miniaturization, and high-speed signal transmission, board-to-board connectors are widely used in communications, automotive electronics, industrial control, and other fields. Compared to traditional fixed board-to-board connectors, they provide reliable electrical connections within a limited space, while allowing for a certain degree of displacement compensation to accommodate assembly tolerances and vibration shocks, thus meeting the stability requirements of complex application scenarios.

[0003] Due to the possibility of minute positioning errors during the manufacturing, assembly, and operation of PCB boards, traditional fixed board-to-board connectors are prone to terminal position misalignment, poor contact, or even terminal damage during mating. To address these issues, conventional floating board-to-board connectors introduce floating or elastic structures to allow male and female terminals to automatically adjust within a certain range. For example, publication numbers CN118399108B, CN117954876B, and CN116031677B (hereinafter referred to as prior art) all describe technical solutions that reduce the sensitivity of male and female terminal processing and assembly tolerances and improve the mating reliability of connectors through floating or elastic structures.

[0004] However, the aforementioned existing technologies still have the following problems: (1) Although the floating structure in the prior art can compensate for assembly errors, the terminal shape optimization is insufficient and the balance of terminal stress distribution, contact stability and insertion and extraction force is not fully considered. This may lead to insufficient contact pressure between male and female terminals, which in turn affects the stability of contact resistance. Especially in high vibration or high temperature environments, the contact points are prone to fretting wear, which accelerates failure. (2) Existing reliability testing methods are mainly based on traditional connector standards and lack systematic contact reliability assessment methods. They mainly rely on experimental testing, and there is little numerical simulation analysis of terminal contact behavior and floating compensation capability. There is a lack of optimization design methods based on finite element analysis (FEA) and multiphysics simulation, which limits the feasibility of performance improvement and engineering application. Summary of the Invention

[0005] The purpose of this invention is to provide a simulation evaluation method for board-to-board connector insertion and removal. It uses APDL language for parametric modeling, establishes a transient dynamic finite element model, and improves the contact stability and durability of the connector by optimizing the terminal contact shape and floating structure.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A simulation evaluation method for board-to-board connector mating and unmating includes the following steps: Step 1: Generate parametric CAD and CAE models; Step 2: Distinguish between contact and non-contact areas in the CAD model and CAE model; Step 3: Simulate the mating process of male and female terminals to complete the optimized design of the male and female terminal contact structures; Step 4: Select the stress distribution change between the male and female terminals and whether the floating structure undergoes plastic deformation as the first evaluation target parameters; Step 5: Establish a global finite element simulation model for floating simulation and analyze the floating characteristics of the global finite element simulation model; Step 6: Divide the floating characteristics into offset floating and torsional floating. Under extreme floating conditions, simulate the change distribution of contact normal pressure between the male and female terminals. Step 7: Complete the optimized design of the floating structure; Step 8: Optimal floating structure of the output connector and contact structure of the male and female terminals; In step 1, the CAD model and CAE model include the male terminal, female terminal, floating seat and female terminal base. The female terminal is provided with a floating structure. After the male terminal and female terminal are matched, a terminal pair is formed. The generated CAD model and CAE model are modeled as a whole by the transient dynamic finite element analysis method.

[0007] Preferably, in step 3, the optimized design method for the male and female terminal contact structures is as follows: Step 3.1: Select a set of male and female terminals for mating simulation to obtain the insertion and extraction force between the terminal pairs, the contact normal force of the terminal pairs, and the plastic deformation parameters of the terminal pairs as the second evaluation target parameters; Step 3.2: Evaluate whether the simulation results of the terminal pair meet the working condition requirements according to the second evaluation target parameters. If the simulation results meet the working condition requirements, the terminal pair structure used to establish the overall finite element simulation model is obtained. Step 3.3: If the simulation results do not meet the operating conditions, optimize the contact shape of the terminal pair, and then perform a simulation on the optimized terminal pair to obtain new second evaluation target parameters.

[0008] Preferably, in step 6, the optimization design method for the floating structure is as follows: Step 6.1: Based on the simulation results under extreme floating conditions, determine whether the terminal pair and floating structure have undergone significant plastic deformation. If significant plastic deformation has occurred, select the terminal pair with the lowest contact performance as the key evaluation object. Step 6.2: If no significant plastic deformation occurs, optimize the floating structure and then select the optimized floating structure to establish a new overall finite element simulation model.

[0009] Step 6.3: After selecting the terminal pair with the lowest contact performance as the key evaluation object, determine whether the contact performance between the male and female terminals during the floating process meets the minimum requirements. If the minimum requirements are met, output the optimal floating structure of the connector. Step 6.4: If the contact performance between the male and female terminals does not meet the minimum requirements, the floating structure is optimized, and then the optimized floating structure is selected to establish a new overall finite element simulation model.

[0010] Preferably, in step 2, the male terminal, female terminal, floating structure and female terminal base are divided into contact area and non-contact area. The contact area uses a high-precision hexahedral mesh, and the non-contact area uses automatic mesh generation.

[0011] Preferably, in steps 3 and 6, the simulation process employs implicit dynamics for solution.

[0012] Preferably, in step 6, the offset floating includes single-axis offset in the X, Y, and Z directions and composite offset in the XY, XZ, YZ, and XYZ directions; the torsion floating includes single-horizontal-plane torsion and multi-horizontal-plane torsion. The single-horizontal-plane torsion has XY, XZ, and YZ planes, and the multi-horizontal-plane torsion has XYZ plane.

[0013] Preferably, the floating structure is a Z-shaped structure, and the end of the floating structure away from the male terminal is mounted on the female terminal base.

[0014] Preferably, the end of the female terminal away from the floating structure is provided with a V-shaped bend.

[0015] Preferably, the male terminal is provided with a guide ramp and a retaining wall.

[0016] Preferably, the female terminal is provided with a smooth transition section for connection with the floating structure.

[0017] Compared with the prior art, the present invention has the following beneficial effects: In this invention, the male and female terminals are manufactured using a stamping process, which offers advantages such as high material utilization, high forming precision, and suitability for automated assembly. The ends of the male and female terminals furthest from the contact surface are pre-designed with welding connectors, simplifying the assembly process. The contact structure of the female terminal is made of an elastic material. This invention optimizes the contact shape and floating structure of the male and female terminals through simulation, improving the contact stability and durability of the terminals and ensuring reliable electrical connection even under extreme environments such as high vibration.

[0018] Meanwhile, by innovatively adopting a contact reliability assessment method based on finite element analysis and multiphysics simulation, this method comprehensively considers factors such as contact normal pressure, insertion and extraction force, and plastic deformation between male and female terminals. Compared with traditional methods that rely on experimental testing, this method improves assessment accuracy and optimizes design capabilities, reduces the number of physical prototype tests, lowers material and processing costs, shortens the R&D cycle, and improves design efficiency, providing reliable technical support for the engineering application of high-performance floating board-to-board connectors. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0020] Figure 1 This is a flowchart of the board-to-board connector insertion and removal simulation evaluation method described in the embodiment of the present invention.

[0021] Figure 2 This is a schematic diagram of the terminal pair structure in this invention.

[0022] Figure 3 This is a schematic diagram of the overall finite element simulation model in this invention.

[0023] Figure 4 This is a comparison chart of signal simulation return loss in Embodiment 1 of the present invention.

[0024] Figure 5 This is a comparison chart of signal simulation return loss in Embodiment 2 of the present invention.

[0025] Figure 6 This is a comparison chart of the positive pressure data generated between the terminal pairs in Embodiment 1 and Embodiment 2 of the present invention.

[0026] Figure 7 This is a schematic diagram of the floating structure in this invention.

[0027] Figure 8 This is a schematic diagram of the simulation model structure generated in the X direction according to the present invention.

[0028] Figure 9 This is a schematic diagram of the simulation model structure generated in the Y direction according to the present invention.

[0029] Figure 10 This is a schematic diagram of the simulation model structure generated in the Z direction according to the present invention.

[0030] Figure 11This is a schematic diagram of the displacement-load versus time curves during floating simulation of the present invention.

[0031] Figure 12 This is the equivalent stress cloud diagram of the female terminal in the Y direction with an offset of 0.5mm in the present invention.

[0032] Figure 13 This is a graph showing the change in contact pressure of the terminal pair as a function of offset in this invention.

[0033] The attached diagram lists the components represented by each number as follows: 101-Female end base, 102-Male end, 103-Female end, 104-Floating structure, 105-V-shaped bend, 106-Guide slope, 107-Barrier, 108-Smooth transition section, 109-Bending section, 110-Reverse deformation structure, 111-Reverse bending structure, 112-Extended section, 113-Floating seat, 114-Vertical section, 115-Male seat, 116-Rounded corner, 117-Connecting section. Detailed Implementation

[0034] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of the embodiments of the invention. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0035] In the description of the embodiments of the present invention, it should be understood that the terms "length", "vertical", "horizontal", "top", "bottom", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. They are only for the convenience of describing the embodiments of the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of the present invention.

[0036] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of embodiments of the present invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0037] In this embodiment of the invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this embodiment of the invention according to the specific circumstances.

[0038] In embodiments of the present invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0039] The following disclosure provides many different implementations or examples for carrying out different structures of the embodiments of the present invention. To simplify the disclosure of the embodiments of the present invention, specific examples of components and arrangements are described below. Of course, these are merely examples and are not intended to limit the embodiments of the present invention. Furthermore, reference numerals and / or reference letters may be repeated in different examples of the embodiments of the present invention; such repetition is for simplification and clarity and does not in itself indicate a relationship between the various implementations and / or arrangements discussed.

[0040] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0041] Example 1 See Figures 1-13 This embodiment discloses a board-to-board connector insertion and removal simulation evaluation method, including the following steps: Step 1: Generate parametric CAD and CAE models; Step 2: Distinguish between contact and non-contact areas in the CAD model and CAE model; Step 3: Simulate the mating process of male terminal 102 and female terminal 103 to complete the optimized design of the contact structure of male terminal 102 and female terminal 103; Step 4: Select the first evaluation target parameter; Step 5: Establish a global finite element simulation model for floating simulation and analyze the floating characteristics of the global finite element simulation model; Step 6: Divide the floating characteristics into offset floating and torsional floating. Under extreme floating conditions, simulate the change distribution of contact normal pressure on male terminal 102 and female terminal 103 and compare it with the first evaluation parameter. Step 7: Complete the optimized design of floating structure 104; Step 8: The optimal floating structure 104 of the output connector and the contact structure of the male terminal 102 and the female terminal 103; In step 1, the CAD model and CAE model include the male terminal 102, the female terminal 103, the floating seat 113, and the female terminal base 101. The female terminal 103 is provided with a floating structure 104. After the male terminal 102 and the female terminal 103 are matched, a terminal pair is formed. The generated CAD model and CAE model are modeled as a whole by the transient dynamic finite element analysis method.

[0042] In this embodiment, parametric modeling of the contact area between male terminal 102 and female terminal 103 is performed using the Ansys APDL software modeling platform. In step 1, automatic modeling code is written using APDL language to generate CAD and CAE models of male terminal 102, female terminal 103, and female terminal base 101 in the Ansys APDL software modeling platform. The main features of male and female terminals 103 are established by defining key points. After connecting the key points in sequence, a two-dimensional contour is first generated, and then a complete three-dimensional model is constructed through extrusion operations to achieve parametric modeling of the contact area. To improve simulation efficiency and result accuracy, considering that each terminal pair is independent and does not interfere with each other, in step 3, the contact area of ​​a set of terminal pairs is selected as the research object for modeling and simulation, and the optimized design of the terminal pair contact structure is completed accordingly. In this embodiment, the contact structure of male terminal 102 and female terminal 103 is the structure used for contact between male terminal 102 and female terminal 103. In this embodiment, male terminal 102 and female terminal 103 are manufactured based on stamping and bending forming process, which has the advantages of high material utilization, high forming accuracy, and suitability for automated assembly. The male terminal 102 and female terminal 103 have pre-set welding connectors at their ends away from the contact surface, simplifying the assembly process. The contact structure of the female terminal is made of an elastic material. This invention optimizes the contact structure and floating structure 104 of the male terminal 102 and female terminal 103 through simulation, improving the contact stability and durability of the terminal pair and ensuring that the terminal pair can maintain a reliable electrical connection even in extreme environments such as high vibration. Simultaneously, by innovatively adopting a contact reliability assessment method based on finite element analysis and multiphysics simulation, comprehensively considering factors such as the contact normal force, insertion and extraction force, and plastic deformation of the male terminal 102 and female terminal 103, compared with traditional methods relying on experimental testing, it improves the assessment accuracy and optimization design capabilities, reduces the number of physical prototype tests, lowers material and processing costs, shortens the R&D cycle, and improves design efficiency, providing reliable technical support for the engineering application of high-performance floating board-to-board connectors; in step 4, the first The evaluation targets are the stress distribution changes between the male terminal 102 and the female terminal 103, and whether the floating structure 104 undergoes plastic deformation. In step 5, the optimized terminal pair is assembled with the floating seat 113 and the female end base 101 to establish an overall finite element model for floating simulation and conduct floating characteristic analysis. The female end terminal and the floating seat 113 are mounted on the female end base 101. In step 6, simulation of offset floating and torsional floating can comprehensively cover actual operating conditions and improve the versatility and rigor of the evaluation scheme.

[0043] In some embodiments, the optimized design method for the contact structure of the male terminal 102 and the female terminal 103 in step 3 is as follows: Step 3.1: Select a set of male terminals 102 and female terminals 103 for mating simulation to obtain the insertion and extraction force between the terminal pairs, the contact normal force of the terminal pairs, and the plastic deformation parameters of the terminal pairs as the second evaluation target parameters; Step 3.2: Evaluate whether the simulation results of the terminal pair meet the working condition requirements according to the second evaluation target parameters. If the simulation results meet the working condition requirements, the terminal pair structure used to establish the overall finite element simulation model is obtained. Step 3.3: If the simulation results do not meet the operating conditions, the contact shape of the terminal pair is optimized, and then the optimized terminal pair is simulated to obtain new second evaluation target parameters. In step 3.1, the simulation simulates the process of the male terminal 102 perpendicularly mating with the female terminal 103. The Ansys APDL software modeling platform applies constraints to the male terminal 102 and the female terminal 103 according to the limiting environment of the male terminal 102 and the female terminal 103 in actual use. The specific constraint method is to apply a fixed constraint to the bottom of the female terminal 103 and apply a set of displacement loads to the top of the male terminal 102, wherein the displacement loads include vertically downward insertion displacement and vertically upward pull-out displacement.

[0044] In some embodiments, the optimization design method for the floating structure 104 in step 6 is as follows: Step 6.1: Based on the simulation results under extreme floating conditions, determine whether the terminal pair and floating structure 104 have undergone significant plastic deformation. If significant plastic deformation has occurred, select the terminal pair with the lowest contact performance as the key evaluation object. Step 6.2: If no significant plastic deformation occurs, optimize the floating structure 104, and then select the optimized floating structure 104 to establish a new overall finite element simulation model.

[0045] Step 6.3: After selecting the terminal pair with the lowest contact performance as the key evaluation object, determine whether the contact performance between the male terminal 102 and the female terminal 103 during the floating process meets the minimum requirements. If the minimum requirements are met, output the optimal floating structure 104 of the connector. Step 6.4: If the contact performance between the male terminal 102 and the female terminal 103 does not meet the minimum requirements, the floating structure 104 is optimized, and a new overall finite element simulation model is established by selecting the optimized floating structure 104.

[0046] In step 6.1, during the simulation of the overall finite element simulation model floating, the Ansys APDL software modeling platform applies displacement loads to the floating seat 113 according to the limit floating conditions to simulate the floating process; in step 6.3, by selecting the terminal pairs with the lowest contact normal pressure, the principle of minimum performance control is achieved, enhancing the pertinence and scientific nature of the evaluation.

[0047] In some embodiments, in step 2, the male terminal 102, female terminal 103, floating structure 104, and female terminal base 101 are divided into contact areas and non-contact areas. The contact areas use high-precision hexahedral meshes, and the non-contact areas use automatic mesh generation. In this embodiment, by applying high-precision hexahedral meshes to the contact areas and automatic mesh generation strategies to the non-contact areas, the simulation accuracy is ensured while significantly improving computational efficiency. In this embodiment, the contact area is the contact surface between the female terminal 103 and the male terminal 102 after the male terminal 102 and the female terminal 103 are mated; the non-contact area is the structure of the overall finite element simulation model other than the contact surface between the female terminal 103 and the male terminal 102.

[0048] In some embodiments, the simulation process in steps 3 and 6 employs implicit dynamics. In this embodiment, the implicit dynamics calculation method is a commonly used method in the prior art. This implicit dynamics calculation method exhibits higher convergence and stability in handling contact problems, and can more accurately calculate contact pressure, area, and friction effects, significantly improving the accuracy of contact modeling.

[0049] See Figures 7-9In some embodiments, according to claim 1, a board-to-board connector plug-in / plug-out simulation evaluation method is characterized in that: in step 6, the offset floating includes single-axis offset in the X, Y, and Z directions and composite offset in the XY, XZ, YZ, and XYZ directions; the torsion floating includes single-horizontal-plane torsion and multi-horizontal-plane torsion, wherein the single-horizontal-plane torsion has XY, XZ, and YZ planes, and the multi-horizontal-plane torsion has XYZ plane. To adapt to the simulation modeling requirements of the floating structure 104 under complex working conditions, and considering the symmetrical characteristics of the board-to-board connector and the large number of pins in this embodiment, the overall finite element simulation model is partially simplified: the simulation of the floating directions of the X and Y axes is simplified by half, and the floating direction of the Z axis is processed by a 1 / 4 model. After generating the simulation models in the X, Y, and Z directions, the Ansys APDL software modeling platform performs partitioned meshing to divide the male terminal 102, female terminal 103, floating structure 104, and female base 101 into contact areas and non-contact areas. The contact areas use high-precision hexahedral meshes, and the non-contact areas use automatic meshing and mesh repair to ensure that the model has sufficient accuracy and stability during the simulation solution process.

[0050] See Figure 10 In some embodiments, a single X-direction offset is selected as a representative working condition for simulation analysis. The floating simulation is set with two analysis steps: the first analysis step is the simulation of the mating of the male terminal 102 and the female terminal 103, and the second analysis step is to apply a displacement load to the floating seat 113 after the terminals are mated to simulate the floating process.

[0051] In some embodiments, the floating structure 104 is a Z-shaped structure, with one end of the floating structure 104 away from the male terminal 102 mounted on the female base 101. The Z-shaped floating structure 104 has a rounded corner 116 at the bend. Depending on the floating requirements, the angle of the rounded corner 116 can be designed as an acute angle of 60°~85° or an obtuse angle of 95°~120°. In this embodiment, the angle of the rounded corner 116 is less than 90°, which can reduce local stress concentration and improve the impedance continuity of electrical signal transmission. The rounded corner 116 can withstand deformation (bending) in the Z direction, and the connecting portion 117 in the floating structure 104 for connecting two rounded corners 116 can withstand deformation (bending) in the X direction. The Z-shaped floating structure 104 allows for free floating in the X, Y, and Z directions by the deformation in the X and Z directions, including bending and twisting in the Y direction. This Z-shaped floating structure 104 significantly reduces the stress and strain borne by the floating area of ​​the terminal during operation, thereby significantly improving its reliability. In this embodiment, by increasing the distance between the connecting portions 117 at both ends of the arc angle 116 (i.e., the width of the Z-shaped floating structure 104), the floating structure 104 can be smoothly connected, optimizing data transmission performance.

[0052] In some embodiments, a V-shaped bend 105 is provided at the end of the female terminal 103 away from the floating structure 104. In this embodiment, by providing the V-shaped bend 105 at the top of the female terminal 103, the female terminal 103 undergoes elastic deformation during its engagement with the male terminal 102, thereby providing a positive pressure that causes the female terminal 103 to press against the male terminal 102.

[0053] In some embodiments, the male terminal 102 is provided with a guide slope 106 and a retaining wall 107. In this embodiment, the male terminal 102 is used to be installed on the male terminal base 115, and the retaining wall 107 is set on the male terminal base 115. In step 1, it is not necessary to generate a CAD model and CAE model of the male terminal base 115. It is only necessary to apply constraints to the male terminal 102 and the female terminal 103 according to the limiting environment of the male terminal 102 and the female terminal 103 in actual use to realize the mating simulation of the male terminal 102 and the female terminal. The male terminal 102 is a rigid planar structure, and the male terminal base 115 and the retaining wall 107 are made of plastic material. The retaining wall 107 is used to limit the male terminal 102. The guide slope 106 can ensure that the direction of the insertion force is correct when the male terminal 102 and the female terminal 103 are mated, avoid the insertion deviation, and guide the male terminal 102 to accurately contact the V-shaped bend 105 provided on the female terminal 103, thereby improving the structural mating stability.

[0054] In some embodiments, the female terminal 103 is provided with a smooth transition section 108 for connection with the floating structure 104. In this embodiment, the connection between the floating structure 104 and the female terminal 103 is widened, and a smooth transition section 108 is provided at the connection between the floating structure 104 and the female terminal 103. The floating structure 104 and the female terminal 103 are smoothly connected by an integral molding process, further optimizing electrical performance and structural stability.

[0055] Example 2 See Figures 4-7 In step 3, the mating process of male terminal 102 and female terminal 103 is simulated. Key data such as insertion and extraction force, contact pressure of terminal pair and plastic deformation area of ​​terminal pair are extracted by APDL post-processing program. In order to ensure that the insertion and extraction force, contact pressure of terminal pair and plastic deformation parameters of terminal pair meet the working conditions, this embodiment further optimizes the structure of female terminal 103 and male terminal 102 and the corresponding technical solution in Example 1 based on Example 1.

[0056] In some embodiments, the male terminal 102 has a bent portion 109 at the end that contacts the female terminal 103. In this embodiment, by providing the bent portion 109, the male terminal 102 and the female terminal 103 can be arranged collinearly, thereby improving impedance continuity and coupling performance and reducing return loss. In Embodiment 1, the terminal pair exhibits approximately 5dB of excessive return loss in the 2–3GHz and 6–8GHz frequency bands. In this embodiment, the optimized mechanism of the terminal pair results in a smoother curve, fewer resonant points, and stable control of the return loss within 3dB.

[0057] In some embodiments, the bending depth of the V-shaped bend 105 on the female terminal 103 and the length of the vertical segment on the female terminal 103 can be adaptively adjusted according to actual needs. This avoids insufficient contact interference between the male terminal 102 and the female terminal 103 due to an excessively small bending depth of the V-shaped bend 105, and avoids excessive lever arm of the female terminal 103 due to an excessively long vertical segment.

[0058] In some embodiments, the smooth transition section 108 is provided with an anti-deformation structure 110. By providing the anti-deformation structure 110, the smooth transition end of the female terminal 103 can be made to tilt in the opposite direction to the original deformation direction of the female terminal 103 after being subjected to force, thereby effectively suppressing the occurrence of the plastic deformation zone.

[0059] See Figure 6 In this embodiment, the structure of the male terminal 102 and the female terminal 103 is optimized and simulated again. Compared with the first embodiment, the simulated structure can increase the contact positive pressure of the terminal pair to 0.44N, which is 120% higher than the original value, significantly enhancing the contact stability and assembly consistency of the connector.

[0060] Example 3 See Figures 8-13 In the simulation process of step 6, when the parameterization post-processing program of the overall finite element simulation model is implemented based on APDL language to extract the contact normal pressure and equivalent plastic deformation results between each terminal pair, the equivalent stress generated at the bending point of the floating structure 104 in Example 1 exceeds the material yield limit of 600MPa during the floating process, causing the floating structure 104 to undergo significant plastic deformation, which may lead to potential failure during long-term use of the connector. In order to avoid local plastic deformation of the floating structure 104 and improve the stability of the connector, this embodiment further optimizes the structure of the female terminal 103 and the corresponding technical solutions in Example 1 and Example 2 based on Example 1 and Example 2. In some embodiments, a reverse bending structure 111 is provided at the connection between the floating structure 104 and the mother base. The reverse bending structure 111 can increase the rigidity of the terminal structure and improve its resistance to insertion / removal and vibration deformation; at the same time, it can effectively disperse local stress and reduce the risk of cracks or fatigue failure caused by stress concentration.

[0061] In some embodiments, the female terminal 103 is provided with an extension portion 112. In this embodiment, the extension portion 112 is vertically arranged. By installing the extension portion 112 inside the floating seat 113, stress concentration during floating can be effectively reduced, plastic strain development can be suppressed, and structural life and long-term stability can be improved.

[0062] See Figure 11 In this embodiment, the terminal pair is fully paired when the contact pressure is 0.42N, completely offset by 0.5mm in the X direction when the contact pressure is 0.390N, reset when the contact pressure is 0.396N, completely offset by -0.5mm in the X direction when the contact pressure is 0.367N, and reset when the contact pressure is 0.373N. The range of positive pressure variation of the male terminal 102 and female terminal 103 during insertion and removal meets the preset contact pressure requirements.

[0063] By optimizing the structure of the female terminal 103 and the floating structure 104, the optimized overall finite element simulation model exhibits stronger floating compensation capabilities in the three-dimensional (X, Y, and Z) directions. This significantly improves the contact normal pressure between the female terminal 103 and the male terminal 102, increasing the minimum pressure from 0.2N to 0.44N, meeting stable transmission requirements. Simultaneously, the use of a large radius (less than 90°) arc angle 116 and a reverse bending structure 111 at the bend of the floating structure 104 effectively alleviates stress concentration, reduces the risk of plastic deformation, and extends the connector's service life. In terms of simulation strategy, combining parametric modeling and finite element analysis enables efficient linkage between structural design and performance prediction, significantly improving design efficiency and reducing prototyping costs. The overall structure possesses advantages such as modularity, strong symmetry, and high assembly adaptability, making it suitable for various high-reliability connection scenarios and demonstrating strong engineering practicality and technological innovation.

[0064] Although preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including both the preferred embodiments and all changes and modifications falling within the scope of the invention.

[0065] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. It should be noted that any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A simulation evaluation method for board-to-board connector insertion and removal, characterized in that, Includes the following steps: Step 1: Generate parametric CAD and CAE models; Step 2: Distinguish between contact and non-contact areas in the CAD model and CAE model; Step 3: Simulate the mating process of the male terminal (102) and the female terminal (103) to complete the optimized design of the contact structure of the male terminal (102) and the female terminal (103); Step 4: Select the first evaluation target parameter; Step 5: Establish a global finite element simulation model for floating simulation and analyze the floating characteristics of the global finite element simulation model; Step 6: Divide the floating characteristics into offset floating and torsional floating. Under extreme floating conditions, simulate the change distribution of contact normal pressure between the male terminal (102) and the female terminal (103) and compare it with the first evaluation parameter. Step 7: Complete the optimized design of the floating structure (104); Step 8: Optimal floating structure (104) of the output connector and contact structure of male terminal (102) and female terminal (103); In step 1, the CAD model and CAE model include the male terminal (102), female terminal (103), floating seat (113) and female terminal base (101). The female terminal (103) is provided with a floating structure (104). After the male terminal (102) and female terminal (103) are matched, a terminal pair is formed. The generated CAD model and CAE model are modeled as a whole by the transient dynamic finite element analysis method.

2. The board-to-board connector insertion and removal simulation evaluation method according to claim 1, characterized in that: In step 3, the optimized design method for the contact structure of the male terminal (102) and the female terminal (103) is as follows: Step 3.1: Select a set of male terminals (102) and female terminals (103) for mating simulation to obtain the insertion and extraction force between the terminal pairs, the contact normal force of the terminal pairs, and the plastic deformation parameters of the terminal pairs as the second evaluation target parameters; Step 3.2: Evaluate whether the simulation results of the terminal pair meet the working condition requirements according to the second evaluation target parameters. If the simulation results meet the working condition requirements, the terminal pair structure used to establish the overall finite element simulation model is obtained. Step 3.3: If the simulation results do not meet the operating conditions, optimize the contact shape of the terminal pair, and then perform a simulation on the optimized terminal pair to obtain new second evaluation target parameters.

3. The board-to-board connector insertion and removal simulation evaluation method according to claim 1, characterized in that: In step 6, the optimization design method for the floating structure (104) is completed as follows: Step 6.1: Based on the simulation results under extreme floating conditions, determine whether the terminal pair and floating structure (104) have undergone significant plastic deformation. If significant plastic deformation has occurred, select the terminal pair with the lowest contact performance as the key evaluation object. Step 6.2: If no significant plastic deformation occurs, optimize the floating structure (104) and then select the optimized floating structure (104) to establish a new overall finite element simulation model; Step 6.3: After selecting the terminal pair with the lowest contact performance as the key evaluation object, determine whether the contact performance between the male terminal (102) and the female terminal (103) during the floating process meets the minimum requirements. If the minimum requirements are met, output the optimal floating structure of the connector (104). Step 6.4: If the contact performance between the male terminal (102) and the female terminal (103) does not meet the minimum requirements, the floating structure (104) is optimized, and the optimized floating structure (104) is selected to establish a new overall finite element simulation model.

4. The board-to-board connector insertion and removal simulation evaluation method according to claim 1, characterized in that: In step 2, the male terminal (102), female terminal (103), floating structure (104) and female terminal base (101) are divided into contact area and non-contact area. The contact area adopts high-precision hexahedral mesh, and the non-contact area adopts automatic mesh generation.

5. The board-to-board connector insertion and removal simulation evaluation method according to claim 1, characterized in that: In steps 3 and 6, the simulation process employs implicit dynamics for solution.

6. The board-to-board connector insertion and removal simulation evaluation method according to claim 1, characterized in that: In step 6, offset floating includes single-axis offset in the X, Y, and Z directions, as well as composite offset in the XY, XZ, YZ, and XYZ directions; torsion floating includes single-horizontal-plane torsion and multi-horizontal-plane torsion. Single-horizontal-plane torsion has XY, XZ, and YZ planes, while multi-horizontal-plane torsion has XYZ plane.

7. The board-to-board connector insertion and removal simulation evaluation method according to claim 1, characterized in that: The floating structure (104) is a Z-shaped structure, and the end of the floating structure (104) away from the male terminal (102) is mounted on the female terminal base (101).

8. The board-to-board connector insertion and removal simulation evaluation method according to claim 7, characterized in that: The female terminal (103) has a V-shaped bend (105) at the end away from the floating structure (104).

9. The board-to-board connector insertion and removal simulation evaluation method according to claim 8, characterized in that: The male terminal (102) is provided with a guide slope (106) and a retaining wall (107).

10. The board-to-board connector insertion and removal simulation evaluation method according to claim 9, characterized in that: The female terminal (103) is provided with a smooth transition section (108) for connection with the floating structure (104).

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