Compliant Pin Header Assembly Alignment and Grounding
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Solution Overview
Problem
Existing electronic assemblies with connectors mounted on printed circuit boards face challenges in achieving proper alignment with external connectors, and current solutions involving insert molded connector terminals are expensive due to the need for unique tooling and equipment for each vehicle application.
Innovation Solution
An electronic assembly featuring a compliant pin header assembly with inter-engaging features that snap into a plastic housing, where the compliant pins engage corresponding features on the printed circuit board, and a metal cover that secures the assembly while providing a ground path, eliminating the need for fasteners directly attaching the PCB to the cover or housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connectors are mounted on the printed circuit board, then electrical connection is achieved, but alignment with external mating connectors becomes difficult
Solution Approach 1:
The connector assembly is segmented into separate components: the housing with integrated connector terminals, the printed circuit board with compliant pins, and the cover. This segmentation allows each component to be manufactured and positioned independently, with the housing serving as the primary alignment reference for external connectors while the PCB is positioned separately using the cover as a clamp.
Solution Approach 2:
The cover acts as an intermediary component that clamps the printed circuit board to the housing without requiring direct attachment of the PCB to the housing. This intermediary structure simplifies assembly by providing a separate mounting path for the PCB while maintaining precise alignment through the housing-cover connection.
2Manufacturing precision
If insert molded connector terminals are used, then alignment is improved, but manufacturing cost increases due to unique tooling requirements
Solution Approach 1:
The housing is designed as a universal component that can accommodate different connector types and configurations through standardized features such as the rib structure and clamp mechanism. This universality allows the same housing design to be used across multiple vehicle applications, eliminating the need for unique tooling for each application while maintaining precise alignment.
Solution Approach 2:
The design uses standardized parameters and dimensions in the housing structure that can be adjusted for different applications without changing the fundamental tooling. The rib geometry, clamp positions, and connector receptacle dimensions are defined as adjustable parameters rather than fixed unique features, allowing cost-effective manufacturing across multiple applications.
3Manufacturing precision
If the cover clamps the printed circuit board, then alignment is maintained, but additional components are required
Solution Approach 1:
The cover combines multiple functions into a single component: it serves as the clamping mechanism for the printed circuit board, provides structural support for the housing assembly, and acts as an alignment reference surface. This merging of functions reduces the need for separate components while maintaining precise PCB positioning.
Solution Approach 2:
The cover is designed as a multi-functional component that performs clamping, support, and alignment functions simultaneously. This universal design reduces overall assembly complexity by eliminating the need for separate clamps, supports, and alignment fixtures that would otherwise be required.
Data Source
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AI summary
An electronic assembly comprises a housing, a cover for the housing, a printed circuit board receivable in the housing, and a compliant pin header assembly. The compliant pin header assembly is mountable in the housing by inter-engaging features on the header assembly and the housing. The compliant pin header assembly has compliant pins for engaging corresponding features on the printed circuit board to connect the compliant pin header assembly electrically to the printed circuit board. The cover, when the electronic assembly is assembled, engages the housing and also engages the printed circuit board at a location spaced from an outer periphery of the printed circuit board.