Electrical Connector Diagonal Alignment Holes
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Solution Overview
Problem
Conventional electrical connectors face challenges in aligning a large number of contacts with printed circuit board pads, leading to increased height issues and difficulties in assembly due to circular holes providing limited displacement and manufacturing tolerance issues, which increase costs.
Innovation Solution
The electrical connector features a rectangular insulative housing with diagonal alignment holes, including a first alignment hole with flat and curved surfaces and a second circular alignment hole, equipped with spring tabs, allowing for greater displacement and flexibility during assembly, thereby absorbing manufacturing tolerances and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If posts are integrated on the insulative housing to align electrical contacts with PCB pads, then alignment accuracy is improved, but the connector height increases which contradicts the low profile development trend
Solution Approach 1:
The alignment posts are extracted from the insulative housing and relocated to the printed circuit board. This removes the height-increasing elements from the connector while maintaining the alignment function through corresponding holes and positioning structures on the PCB.
Solution Approach 2:
The alignment function is transitioned from a vertical dimension (posts extending upward from the housing) to a planar dimension (holes and positioning structures on the PCB surface). This dimensional change allows alignment without increasing connector height.
2Adaptability or versatility
If circular holes are used for post engagement, then flexibility is provided, but the displacement adjustment is limited and assembly becomes difficult due to manufacturing tolerance issues
Solution Approach 1:
The circular hole symmetry is broken by introducing asymmetric positioning structures including a rectangular hole and triangular positioning holes on the PCB. This asymmetric configuration provides larger displacement adjustment range and guides the post into proper alignment, making assembly easier despite maintaining flexibility.
Solution Approach 2:
The single circular hole is segmented into multiple functional holes: a rectangular hole for the post with larger displacement capability, and triangular positioning holes for precise alignment. This segmentation allows each hole to specialize in different aspects of the alignment and assembly process.
3Manufacturing precision
If manufacturing tolerance requirements are increased to improve post-hole engagement, then alignment precision is improved, but production costs increase
Solution Approach 1:
The design incorporates tolerance cushioning through the asymmetric hole configuration and positioning structures that are built into the PCB layout. These features预先 provide compensation for manufacturing variations, allowing standard tolerance levels to be used while still achieving precise post-hole engagement.
Solution Approach 2:
The hole geometry parameters are changed from a single circular shape to multiple shapes (rectangular, triangular) with different dimensional characteristics. This parameter diversification allows the system to accommodate a wider range of manufacturing tolerances while maintaining proper engagement.
Data Source
AI summary
An electrical connector includes a rectangular insulative housing having a number of passageways and a number of electrical contacts retained in the passageways, respectively. The insulative housing defines a first alignment hole and a second alignment hole on a diagonal line thereof. The first alignment hole has a pair of flat surfaces extending along the diagonal line and a pair of curved surfaces connected with the flat surfaces for engaging with a mating post to position the electrical connector on a printed circuit board.