Angled Rigid PCB Assembly Using Bent Metal Pin Connections
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Solution Overview
Problem
The high manufacturing costs and labor-intensive processes associated with connecting multiple PCBs in electronic devices, particularly in tight spaces, where flexible PCBs are often required but are expensive and complex to integrate.
Innovation Solution
A PCB assembly method using rigid PCBs with connection metal pins that are bent and fixed at predetermined angles, allowing for electrical connection and rotation, reducing the need for flexible PCBs and simplifying the connection process through the use of connection metal pins, fixing grooves, and angle fixing members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flexible PCBs are used to connect multiple PCBs at various angles, then the PCB assembly can achieve rotated arrangements and electrical connections, but the manufacturing cost increases and the process becomes more complex
Solution Approach 1:
The connection function is segmented between rigid PCBs and separate connection metal pins. The rigid PCBs maintain their structural integrity while the connection pins provide the flexible connection capability, dividing the system into functional segments that solve the contradiction between rigidity and flexibility.
Solution Approach 2:
Connection metal pins serve as intermediary elements between rigid PCBs. These pins enable electrical connection and angular rotation between PCBs without requiring the PCBs themselves to be flexible, thus achieving adaptability while maintaining simplicity of the main PCB structure.
2Adaptability or versatility
If flexible PCBs are used to connect multiple PCBs, then electrical connections and rotations can be achieved, but manufacturing costs increase due to additional components and labor
Solution Approach 1:
Connection metal pins are used as simple, inexpensive components to replace expensive flexible PCBs. The pins are straightforward metal elements that can be easily manufactured and assembled, significantly reducing material costs while achieving the same functional goals.
Solution Approach 2:
The flexibility function is extracted from the PCB structure itself and transferred to separate connection pins. This allows the main PCBs to remain simple rigid structures while the connection capability is provided by dedicated, simpler components that are easier and cheaper to manufacture.
3Ease of manufacture
If rigid PCBs are used without angle fixing structures, then manufacturing is simpler, but the connection stability and electrical reliability deteriorate due to potential deformation
Solution Approach 1:
Fixing grooves are pre-formed on the rigid PCBs at specific angles before assembly. Connection metal pins are inserted into these grooves to lock the PCBs at predetermined angles, preventing deformation and ensuring stable electrical connections while maintaining manufacturing simplicity.
Solution Approach 2:
The fixing groove structure on the rigid PCB automatically guides and constrains the connection metal pin, providing self-aligning and self-locking functionality. This ensures stable connections without requiring complex external fixing mechanisms, maintaining ease of manufacture while improving reliability.
Data Source
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AI summary
A PCB assembly includes at least two PCBs, each having a board, the board being partially perforated in an upper and lower direction to form a connection hole, a connection conductor electrically connected to a printed circuit being formed in the connection hole to be exposed out, the at least two PCBs being arranged such that upper surfaces or lower surfaces of the boards are rotated to form a predetermined angle therebetween; and a connection metal pin having a body and a leg, the body having electric conductivity, the body having a pin shape elongated in one direction, a portion of the body being bent according to the predetermined angle of the at least two PCBs arranged in a rotated state, the leg being bent and extended in another direction from both ends of the body, the bent and extended portion of the leg being inserted through the connection hole respectively formed in the at least two PCBs, a bent and extended terminal of the leg being bent inward to be tightly fixed to a lower surface of the PCB.