Angled Intermediate Circuit Board for Connector Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connector systems for engine control units in motor vehicles are costly and labor-intensive due to the need for flexible connections, which complicate the electrical connection between printed circuit boards and often deteriorate electromagnetic compatibility.
Innovation Solution
A connector system using an intermediate circuit board that is angled and soldered to both the main circuit board and the connector strip, eliminating the need for expensive flexible printed circuit boards and allowing for the integration of EMC filter components, enabling a cost-effective and simpler assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flexible printed circuit boards are used to continue electrical connection in another level, then electrical connection is achieved, but manufacturing cost and processing complexity increase significantly
Solution Approach 1:
The system divides the connector assembly into separate rigid circuit board segments (main circuit board and intermediate circuit board) connected by straight pins, eliminating the need for a single flexible circuit board. This segmentation allows each component to be manufactured using standard rigid PCB processes, reducing cost and complexity while maintaining electrical connectivity.
Solution Approach 2:
An intermediate circuit board is introduced as a mediator between the main circuit board and the connector strip. This intermediate board provides a rigid mounting surface for straight pins, enabling electrical connection between levels without requiring flexible circuit board technology, thus simplifying manufacturing.
2Reliability
If flexible connections are used to connect printed circuit boards at angles, then electrical connection in another level is achieved, but electromagnetic compatibility deteriorates
Solution Approach 1:
The flexible connection is segmented into rigid components (intermediate circuit board and straight pins) that maintain stable electromagnetic characteristics. The rigid structure provides consistent impedance control and reduces electromagnetic interference compared to flexible connections, while still achieving the required angular electrical connection.
Solution Approach 2:
The intermediate circuit board acts as an intermediary that provides a rigid, electromagnetically stable platform for angular connections. It carries filter components that actively improve electromagnetic compatibility while maintaining the electrical connection between the main circuit board and connector strip.
3Ease of manufacture
If intermediate circuit board is used instead of flexible connections, then manufacturing cost is reduced, but additional functions such as EMC filtering must be integrated
Solution Approach 1:
The intermediate circuit board merges multiple functions into a single component: it provides mechanical support for angular connection, establishes electrical connectivity via soldered pins, and integrates EMC filter components directly onto its surface. This consolidation reduces overall system complexity despite adding filtering functionality.
Solution Approach 2:
The intermediate circuit board is designed as a multi-functional element that simultaneously serves as a mechanical connector, electrical conductor, and platform for electromagnetic filtering. This universality allows it to replace multiple separate components (flexible connector + filter elements) with a single integrated solution.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides a more affordable and efficient electrical connection with improved electromagnetic compatibility, allowing for better filter effects, especially for high-frequency signals, and simplifies the assembly of plug-in connection elements while maintaining mechanical stability.
Implementation Method 1
the intermediate circuit board being soldered to them
Data Source
Figure 1
Figure 2
AI summary
The invention relates to connection of a plug connector comprising: a plug connector strip (10, 110), a primary circuit board (20, 120) with connections and an intermediate circuit board (30, 130). The plug connector strip comprises a group of single plug connector elements which extent at an angle to the intermediate circuit board (30, 130) and are attached thereto. The intermediate circuit board (30, 130) extends at an angle to the primary circuit board (20, 120) and is attached thereto. The individual plug connector elements are electrically connected to the junctions via the intermediate circuit board (30, 130). The invention further relates to a method for production of a connection of a plug connector. A plug connector strip (10, 110), a primary circuit board (20, 120) with junctions and an intermediate circuit board (30, 130) are provided. A group of individual plug connector elements is arranged as plug connector strip (10, 110); the plug connector strip (10, 110) is attached to the intermediate circuit board (30, 130), wherein individual plug connector elements extend perpendicular to the intermediate circuit board (30, 130); electrical contacts between the intermediate circuit board (30, 130) and the plug connector strip (10, 110) are produced and the intermediate circuit board (30, 130) is attached to the primary circuit board (20, 120), wherein the intermediate circuit board (30, 130) extends perpendicular to the primary circuit board (20, 120). The method further comprises: Production of electric contacts between the primary circuit board (20, 120) and the intermediate circuit board (30, 130).