Alignable Stacked Circuit Boards via Clearance Gap
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Solution Overview
Problem
Existing methods for stacking circuit boards face challenges in making electrical connections due to manufacturing tolerances, leading to increased costs, reduced manufacturing yield, and potential mechanical stress on solder joints.
Innovation Solution
An electronic assembly design featuring alignable stacked circuit boards with a frame and holder system that allows for precise alignment of connectors through a clearance gap, using fasteners and gripping members to secure the boards and minimize mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom fixtures or jigs are used to attain desired tolerances for connector alignment, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent introduces a frame with provisions (studs or openings) as an intermediary component that mediates between the circuit board and the connector alignment process. This frame provides reference features that facilitate precise connector alignment without requiring complex custom fixtures or jigs, thereby resolving the contradiction between manufacturing precision and device complexity
Solution Approach 2:
The frame is pre-assembled with the circuit board using provisions and fasteners before the connector alignment process. This preliminary action establishes a stable base with built-in alignment references, eliminating the need for complex fixtures during subsequent assembly operations and reducing both device complexity and manufacturing cost while maintaining precision
2Reliability
If connectors are forced to mate between stacked circuit boards, then connection reliability is improved, but mechanical stress on solder joints increases
Solution Approach 1:
The patent incorporates a holder with a recess that allows the second circuit board to have controlled movement freedom during the connector mating process. This dynamic capability enables the connectors to self-align and mate naturally without forcing, thereby maintaining connection reliability while preventing excessive mechanical stress on solder joints
3Productivity
If connectors are positioned outside of desired tolerance during assembly, then manufacturing speed is improved, but manufacturing yield decreases
Solution Approach 1:
The frame and holder assembly is designed with built-in alignment features (provisions, recess, clearance gap) that enable the connectors to self-align during the assembly process. This self-service alignment mechanism ensures that connectors automatically position themselves within the desired tolerance range without requiring slow, precision-intensive manual adjustment, thereby maintaining both manufacturing speed and yield
Data Source
AI summary
A frame is secured to a first circuit board by provisions and respective fasteners to form a first circuit board assembly. A second circuit board has a second connector portion for mating with the first connector portion of the first circuit board. A holder overlies the second circuit board. The holder has a recess with an opening for the second connector portion to extend through. A clearance gap between the interior perimeter of the recess and the outer perimeter of the circuit board assembly allows alignment or registration of the first connector portion and the second connector portion. A lid is connected to the holder via one or more fasteners to secure the first circuit board assembly with respect to the second circuit board.