Compression Contact Wire Harness for PCB-Free Connector Reliability
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Solution Overview
Problem
Existing electrical connectors require expensive contacts and printed circuit boards to establish reliable connections, which can be impractical for applications where a movable component needs to connect with a base component without these components.
Innovation Solution
A wire harness assembly with contacts that have termination, compliant, and substrate engagement sections, where the substrate engagement sections are curved with embossments to provide mechanical and electrical engagement with circuit pads, allowing for compression-based connections without the need for printed circuit boards or expensive contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connectors with contacts and printed circuit boards are used, then reliable electrical connections are achieved, but cost and device complexity increase
Solution Approach 1:
The patent extracts and eliminates the printed circuit board from the traditional connector assembly. The contact elements are directly mounted on the housing structure, removing the intermediate PCB layer while maintaining reliable electrical connections between movable and base components.
Solution Approach 2:
The patent merges the housing structure with the contact mounting function. The housing itself is designed to receive and secure the contact elements, combining structural support and electrical connection functions into a single integrated component, thereby reducing overall device complexity.
2Reliability
If traditional contacts and printed circuit boards are used, then reliable electrical connections are achieved, but manufacturing cost increases
Solution Approach 1:
By extracting the printed circuit board from the assembly, the patent eliminates the cost associated with PCB manufacturing, layer alignment, and specialized assembly processes. The direct mounting approach uses simpler, more cost-effective manufacturing methods.
Solution Approach 2:
The patent employs simpler contact elements that can be directly crimped or secured to the housing without requiring expensive PCB substrates. This approach uses more economical components while maintaining adequate reliability for the application.
3Device complexity
If compression-based connections without printed circuit boards are used, then cost and complexity are reduced, but connection reliability may be compromised
Solution Approach 1:
The patent incorporates compliant sections in the contact elements that provide dynamic adjustment capability. These flexible portions allow the contacts to adapt to slight misalignments and maintain consistent electrical pressure, ensuring reliable connections without rigid PCB structures.
Solution Approach 2:
The patent changes the physical parameters of the contact elements by incorporating curved contact sections with embossments. These geometric modifications increase the contact surface area and distribution of mechanical pressure, enhancing electrical reliability in the compression-based connection system.
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
The solution enables reliable electrical connections between movable and base components using a compression mechanism, reducing costs and complexity by eliminating the need for printed circuit boards and expensive contacts, while maintaining mechanical and electrical engagement.
Implementation Method 1
contacts which compress when mated to a substrate
Implementation Method 2
compliant sections which extend from the termination sections
Data Source
AI summary
A wire harness assembly including a first connector, a second connector, and conductors extending between the first connector and the second connector. Contacts are provided on the second connector. The contacts have termination sections which are mounted on the second connector, compliant sections which extend from the termination sections, and substrate engagement sections which extend from the compliant sections. The substrate engagement sections have curved contact sections which are configured to be positioned in mechanical and electrical engagement with circuit pads of a mating printed circuit board. Embossments are provided on the curved contact sections to provide additional strength and stability to the curved contact sections.