Angled Contact Pin for Reliable Electrical Connections
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Solution Overview
Problem
Conventional straight contact pins used in electronic components, such as those in mobile devices, are prone to disconnection due to mechanical stress from handling and drops, as they can pull away from the solder or conductive glue, leading to unreliable electrical connections.
Innovation Solution
Incorporating an angled portion in the contact pins, where a second portion is angled with respect to the first, allowing conductive materials to contact and surround the pin on multiple sides, thereby increasing the pin's reliability and stability during mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a straight contact pin is used, then the structure is simple and easy to manufacture, but the connection reliability deteriorates under mechanical stress
Solution Approach 1:
The contact pin is designed with an angled portion instead of a straight configuration. This curvature/angle allows the conductive material to wrap around and contact the pin on multiple sides, creating a more reliable electrical connection that resists mechanical stress and disconnection forces.
Solution Approach 2:
The contact pin extends in multiple directions rather than a single straight line. The angled portion creates a three-dimensional configuration where the pin protrudes from the housing at an angle, allowing conductive material to approach and contact the pin from different spatial dimensions, thereby improving connection reliability.
2Reliability
If an angled contact pin is used, then the connection reliability improves, but the manufacturing complexity increases
Solution Approach 1:
The angled configuration can be manufactured using standard bending or forming processes applied to metal pins. The angle provides mechanical advantage for stress distribution while remaining compatible with conventional manufacturing techniques such as stamping, bending, or extrusion, thus balancing reliability improvement with manufacturing feasibility.
Data Source
AI summary
Described herein are various embodiments of contacts that include different portions angled with respect to one another and methods of manufacturing devices that include such contacts. In some embodiments, a module may include a first portion of a contact that is disposed within a housing and a second portion that is disposed outside of the housing, with the second portion angled with respect to the first portion. Manufacturing such devices may include depositing a conductive material to electrically connect the contact to a contact pad of a substrate. In some embodiments, a deposition process for depositing the conductive material may have a minimum dimension, which defines a minimum dimension of a conductive material once deposited. In some such embodiments, a distance between a terminal end of the contact pin and the contact pad may be greater than the minimum dimension of the deposition process.