Aperture-Mounted Electrical Connector for Thin PCBs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors for handheld devices add unnecessary thickness due to their housing design, which complicates the manufacturing of thinner and lighter devices by requiring additional space on printed circuit boards for connections.
Innovation Solution
An electrical connector with a housing structured to be supported within an aperture of a printed circuit board, featuring electrical contacts with extendable connectable portions and projections that lie flush with the board surface, minimizing overall thickness and using surface mount technology for connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connectors with housings are used on printed circuit boards, then electrical connections are established, but the device thickness increases
Solution Approach 1:
The electrical connector housing is nested within the printed circuit board aperture, with the housing positioned inside the board thickness rather than adding to it. The connectable portions extend through the board surface to make connections, while the bulk of the connector structure is contained within the board's internal space.
Solution Approach 2:
The connector design transitions from a surface-mounted configuration (adding thickness in the Z-direction) to an aperture-mounted configuration where the housing is positioned in the plane of the board (X-Y directions) and extends through the thickness, utilizing the board's internal volume rather than adding external volume.
2Ease of operation
If electrical connectors are mounted on the surface of printed circuit boards, then connections are established, but the housing occupies additional space on the board
Solution Approach 1:
The housing is nested within the aperture opening, utilizing the board's internal space rather than occupying surface area. This allows the connector to be supported by the board structure itself without requiring additional surface mounting space.
3Reliability
If thicker electrical connectors are used to ensure secure mounting, then connection reliability is improved, but device thickness increases
Solution Approach 1:
The housing is positioned within the aperture and secured by the board's structural features (such as recesses or clips) rather than requiring a thick housing for mechanical support. The mounting reliability is achieved through the integration with the board's internal structure rather than through increased connector thickness.
Solution Approach 2:
The mounting strength is derived from the aperture's depth and the board's internal structure rather than from the housing thickness. The connector utilizes the board's thickness as a resource for secure mounting rather than adding to the overall device thickness.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An electrical connector is provided. The electrical connector has a housing which is supportable within an aperture of a printed circuit board. The electrical connector also has one or more electrical contacts that are disposed on the housing with at least some of the contacts each having a connectable portion extending from the housing in a direction generally parallel with a first axis. The electrical connector also has a number of opposed projections extending from the housing in a direction generally parallel with a second axis. The first axis is generally perpendicular to the second axis. The one or more contacts include a deflectable biasing portion which extends outwardly from the housing and which is structured to be electrically connected with the device.