Compression USB Connector Diagnostics for Repairable PCB Mounting
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Solution Overview
Problem
Existing USB connectors, particularly Type-C connectors, are difficult and costly to repair due to their soldered integration with PCBs, leading to complex and expensive replacement solutions, and there is a need for easy, cost-effective repairability without sacrificing functionality or product feature sets.
Innovation Solution
A non-soldered compression USB connector assembly with diagnostic contacts, such as diagnostic surface pads, leaf-springs, and extra diagnostic contacts, that allow for easy attachment and detachment from the PCB, enabling connectivity diagnosis and replacement without solder joints, maintaining signal integrity and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If USB connectors are soldered directly to PCBs, then connection reliability is improved, but repairability deteriorates and replacement becomes complex and costly
Solution Approach 1:
The USB connector assembly is segmented into a separate removable component from the PCB, allowing the connector to be replaced independently without replacing the entire PCB. The mounting bracket with diagnostic contacts forms a distinct module that can be detached and replaced separately.
Solution Approach 2:
A mounting bracket with diagnostic contacts serves as an intermediary component between the USB connector and the PCB. This intermediary enables both reliable electrical connection through diagnostic contacts and easy removal through the mounting bracket mechanism, resolving the contradiction between reliability and repairability.
2Ease of repair
If large, complex off-PCB solutions are used for non-soldered USB connectors, then repairability is improved, but device complexity and cost increase
Solution Approach 1:
The mounting bracket is merged with the diagnostic contacts to form a single integrated component. This combination eliminates the need for separate diagnostic contact assemblies, reducing overall complexity while maintaining both diagnostic capability and repairability.
Solution Approach 2:
The mounting bracket serves multiple functions: it provides mechanical support for the USB connector, establishes electrical connections through integrated diagnostic contacts, and enables easy removal. This multi-functionality reduces the need for additional components, simplifying the overall assembly.
3Difficulty of detecting and measuring
If diagnostic contacts are added to the mounting bracket, then connectivity diagnosis capability is improved, but manufacturing complexity increases
Solution Approach 1:
The diagnostic contacts utilize the same material properties and manufacturing parameters as the mounting bracket itself, allowing both to be produced in a single manufacturing process. This approach adds diagnostic functionality without requiring separate manufacturing steps or materials.
Data Source
AI summary
Embodiments of systems and methods to diagnose connectivity of a non-soldered compression Universal Serial Bus (USB) connector are described. In some non-limiting embodiments, a USB connector assembly includes: a mounting bracket configured to removably attach to a printed circuit board (PCB); and a plurality of diagnostic contacts disposed at least in part within the mounting bracket, where the diagnostic contacts are configured to electrically connect to corresponding ones of a plurality of electrical diagnostic contact pads of the PCB, where an individual diagnostic contact of the plurality of diagnostic contacts applies a force to a corresponding one of the electrical diagnostic contact pads of the PCB when the mounting bracket is mated to the PCB, and where the diagnostic contacts are part of a conductivity path of a diagnostic circuit when the mounting bracket is mated to the PCB.