Bridging Connector Alignment for Non-Coplanar Circuit Boards
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Solution Overview
Problem
Existing methods for electrically coupling circuit boards are complex and lack simplicity, particularly for non-coplanar arrangements, often requiring additional connectors, welding, or cumbersome wire harnesses.
Innovation Solution
A bridging connector with a housing and contact bodies that align via guide holes and pins, allowing for easy positioning and contact with electrical contact holes on circuit boards, featuring angled contact surfaces, deformable terminals, and adjustable angles for flexible compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional connectors and flexible wire harnesses are used to electrically couple circuit boards, then electrical connection is established, but device complexity increases
Solution Approach 1:
The patent combines the electrical connection function and mechanical positioning function into a single integrated connector. The connector includes contact bodies for electrical connection and guide holes with guide pins for positioning, eliminating the need for separate wire harnesses and reducing overall system complexity while maintaining reliable electrical coupling between circuit boards
Solution Approach 2:
The connector is designed to perform multiple functions simultaneously: it provides electrical connection through contact bodies, mechanical positioning through guide holes and guide pins, and structural support through the housing. This multi-functional design replaces what would traditionally require multiple separate components, reducing device complexity
2Reliability
If direct welding is used to connect circuit boards, then electrical connection is established, but ease of manufacture decreases
Solution Approach 1:
The patent divides the connection system into separable components: a connector with contact bodies that can be independently assembled onto circuit boards, and a housing with guide holes for positioning. This segmentation allows for easier manufacturing and assembly compared to direct welding, as components can be pre-assembled and then easily connected without requiring welding equipment or skilled welding operations
Solution Approach 2:
The connector is designed with pre-positioned guide holes and guide pins that automatically align the connector with the circuit board before insertion. This preliminary positioning action simplifies the assembly process by eliminating the need for complex alignment procedures during assembly, making manufacturing easier while ensuring reliable electrical connection
3Ease of operation
If guide holes with open horn shape are provided, then ease of operation improves for guiding pins, but manufacturing precision requirements increase
Solution Approach 1:
The guide holes are designed with an open horn shape that transitions from a larger opening to a narrower base, creating a dynamic guiding process. The larger opening at the top allows easy insertion and alignment of the guide pins during assembly, while the narrower base provides precise positioning once inserted. This dynamic geometry balances ease of operation with acceptable manufacturing precision requirements
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
Enables a straightforward, interference-fit connection between circuit boards without additional soldering, accommodating non-coplanar arrangements and tolerances, thus simplifying the electrical coupling process.
Implementation Method 1
The top section of the terminal is in the shape of a needle eye and at least the tip thereof is tapered. The top section is elastically deformable, and a distance from one opposite side is greater than the diameter of an electrical contact hole. Therefore, the terminal is inserted into an electrical contact hole in an interference fit
Data Source
AI summary
A design of a bridging connector, a connection assembly, a vehicle lamp, and a vehicle. The bridging connector is used to connect circuit board components arranged on a carrier, and the circuit board component is provided with electrical contact holes and has a board surface. The bridging connector includes a housing with contact surfaces and contact bodies arranged in the housing. In the installed state, the contact surfaces are in contact with the board surface, and the contact bodies are located in the electrical contact holes in a manner of being in contact with the electrical contact holes. The housing is provided with guide holes, and the guide holes cooperate with guide pins provided on the carrier so that the contact bodies occupy a predetermined position with respect to the electrical contact holes.