Back-to-Back PCB USB Connector Automated Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly of pocket-sized electronic cards with double-sided USB connectors is labor-intensive and prone to errors due to the need for manual wiring and soldering, which increases costs and reduces automation efficiency.
Innovation Solution
A double-sided USB connector design featuring a main PCB with electrical contacts and a via PCB with terminals, allowing connections to be made using signal traces instead of wires, enabling automated assembly processes like reflow soldering and reducing the need for manual wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual wiring and soldering are used to assemble the USB connector with PCB, then connection reliability is improved, but labor intensity increases and automation efficiency decreases
Solution Approach 1:
The patent replaces manual mechanical wiring operations with automated PCB trace connections. Electrical connections are established through PCB signal traces and pads rather than manual wire attachment, enabling automated assembly while maintaining connection reliability through precise PCB manufacturing processes.
2Strength
If manual soldering processes are used, then connection strength is improved, but manufacturing cost increases and production time increases
Solution Approach 1:
The patent replaces manual soldering with automated reflow soldering processes. Solder connections are formed through automated PCB manufacturing techniques where solder paste is applied to pads and reflowed in a controlled environment, reducing labor costs while maintaining connection strength through consistent thermal processing.
Solution Approach 2:
The patent changes the soldering process parameters from manual control to automated temperature-time profiles. Reflow soldering uses precisely controlled temperature curves to melt and re-solidify solder, ensuring consistent connection strength while enabling high-volume automated production and reducing per-unit manufacturing costs.
3Manufacturing precision
If manual wiring is used, then connection precision is improved, but error rate increases and assembly time increases
Solution Approach 1:
The patent replaces manual wiring precision with automated PCB fabrication precision. Connection locations are defined by PCB pad layouts created through CAD software and manufactured with high precision using automated PCB routing and drilling equipment, eliminating human error while maintaining accurate connection placement.
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 design facilitates automated assembly of portable electronic cards, reduces labor costs, and enhances production efficiency by eliminating the need for manual wiring and error-prone manual soldering processes.
Implementation Method 1
enables automated assembly processes like reflow soldering
Data Source
AI summary
A double-sided USB connector may include a first PCB that may provide a first set of electrical contacts on its first side and solder pads on its second side. The first PCB may further include a components side, solder pads, and signal traces. The double-sided USB connector may also include a second PCB that may provide a second set of electrical contacts on its first side and terminals on its second side. Contacts selected from the second set of contacts may be connected to selected terminals, for example through via paths in the second PCB. Contacts from the first and second sets of contacts may selectively be connected to components on the first PCB using signal traces rather than wires. The first PCB may be joined to the second PCB by using the terminals, and the two PCBs may be packaged using a common molded body.