Compact Electrical Connector with Integrated PCB Contact
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Solution Overview
Problem
Existing connectors for electrical conductors and printed circuit boards (PCBs) are laborious to assemble, require additional mating connectors, and occupy excessive space, especially in compact assemblies.
Innovation Solution
A compact electrical connector with a T-shaped insulating body featuring cavities for direct contact elements that eliminate the need for a mating connector, utilizing detent shapings for secure PCB attachment and cable-receiving channels for efficient core contact, allowing for easy assembly and reduced space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional connector with separate mating connector is used, then reliable electrical connection is achieved, but device complexity and component count increase
Solution Approach 1:
The patent combines the functions of the connector and mating connector into a single integrated component. The connector directly contacts the PCB through integrated contact elements and detent shapings, eliminating the need for a separate mating connector while maintaining reliable electrical connection. This merging reduces component count and assembly steps.
Solution Approach 2:
The single connector performs multiple functions that were previously distributed across two separate components: it provides electrical contact through integrated contact elements, mechanical attachment through detent shapings, and cable routing through integrated channels. This multi-functionality reduces device complexity while maintaining connection reliability.
2Reliability
If a traditional connector with mating connector is used, then electrical connection is established, but assembly process becomes laborious and time-consuming
Solution Approach 1:
By merging the connector and mating connector into one integrated component, the assembly process is simplified from multiple steps (preparing line cores, connecting to contact elements, inserting into insulating body, then assembling mating connector) to a single insertion operation where the integrated connector directly contacts the PCB and secures through detent shapings.
Solution Approach 2:
The contact elements are pre-integrated into the insulating body during manufacturing, with cable-receiving channels and detent shapings already in place. This preliminary integration eliminates the need for laborious on-site assembly operations such as exposing line cores and individually connecting them to contact elements, thereby increasing assembly productivity.
3Reliability
If a mating connector is added for PCB connection, then reliable contact is achieved, but space requirements increase
Solution Approach 1:
The integration of the mating connector functions into the main connector body eliminates the need for a separate mating connector component. The contact elements, detent shapings, and cable-receiving channels are all incorporated into a single compact structure that directly contacts the PCB, reducing the overall volume required for the connection assembly.
Solution Approach 2:
The contact elements are nested within cavities in the insulating body, with cable-receiving channels passing through the insulating body to contact the cores. The detent shapings are integrated into the insertion side structure. This nesting arrangement achieves reliable electrical and mechanical contact while minimizing the external dimensions of the connector.
Data Source
AI summary
Provided a connector for establishing an electrical connection between an electrical conductor and a printed circuit board. The connector includes an insulating element which has a plurality of cavities for accommodating contact elements. The printed circuit board can be inserted in the connector via a slot in a connection face of the insulating element and can be connected to the first contact faces of the contact element provided in the connection face. Opposite the first contact face, the contact elements have a second contact face which is provided for the insulation-piercing contacting of the electrical conductor. The arrangement of the contact elements in the insulating element allows a particularly space-saving design of the connector.