Electrical Connector Alignment Fixture for Helium-Sealed HDDs
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Solution Overview
Problem
Manufacturing electrical connector assemblies for helium-filled hard disk drives is challenging due to misalignment issues during the soldering process, which can lead to helium leakage through gaps between components.
Innovation Solution
A method involving a fixture with frames that position and align arrays of electrical interposers and receptacles, allowing for simultaneous reflowing of solder to mechanically and electrically couple them, reducing misalignment and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional separate positioning and soldering methods are used for electrical interposers and receptacles, then manufacturing flexibility is maintained, but misalignment occurs during the soldering process leading to gaps and helium leakage
Solution Approach 1:
The patent combines the positioning fixture and soldering process into a single integrated system. The fixture simultaneously positions multiple interposers and receptacles while maintaining alignment during the reflow soldering process, eliminating the need for separate positioning and soldering operations that caused misalignment and helium leakage.
Solution Approach 2:
The fixture is designed to perform multiple functions: positioning interposers and receptacles, maintaining alignment during heating, and facilitating the soldering process. This multi-functional approach resolves the contradiction by achieving precise alignment without requiring multiple separate devices or complex sequential operations.
2Productivity
If arrays of electrical interposers and receptacles are positioned and soldered simultaneously, then manufacturing efficiency is improved, but alignment precision becomes more difficult to maintain
Solution Approach 1:
The fixture is divided into multiple positioning stations, each capable of independently holding and positioning an interposer-receptacle pair. This segmentation allows simultaneous processing of multiple components while maintaining precise alignment at each station through dedicated positioning features, resolving the contradiction between batch processing efficiency and alignment precision.
3Ease of manufacture
If gaps exist between electrical components due to misalignment, then manufacturing process is simpler, but helium leakage occurs compromising the sealed environment
Solution Approach 1:
The fixture pre-positions all interposers and receptacles with precise alignment before the soldering process begins. This preliminary positioning action ensures that components are correctly aligned and tightly fitted before heating, preventing gaps that would cause helium leakage while maintaining manufacturing simplicity through the fixture's guided assembly process.
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
This method ensures accurate alignment and efficient coupling of electrical components, reducing helium leakage and improving the manufacturing efficiency of electrical connector assemblies for sealed hard disk drives.
Implementation Method 1
reflowing solder to mechanically and electrically couple the array of the first electrical receptacles to the array of the electrical interposers
Data Source
AI summary
A method for manufacturing electrical connector assemblies is disclosed. The electrical connector assemblies include an electrical interposer and a first electrical receptacle. The method includes positioning a fixture coupled to or including an array of the first electrical receptacles such that each of the first electrical receptacles aligns with one of the electrical interposers on an assembly with an array of the electrical interposers. The method further includes reflowing solder to mechanically and electrically couple the array of the first electrical receptacles to the array of the electrical interposers.