Connector Insert Alignment Structure for PCB Pin Tolerance Stack-Up
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Solution Overview
Problem
Existing electronic systems face challenges in aligning electrical pins within a bay, leading to potential misalignment and failure in connecting wire harnesses, especially when multiple sets of pins are coupled on a single PCB, resulting in increased tolerance stack-up and difficulty in precise alignment.
Innovation Solution
The system employs a two-piece alignment structure comprising a housing with a slot and a connector insert, utilizing compliant retainer clips and springs to align individual sets of electrical pins within respective bays, ensuring precise alignment in two orthogonal directions, thereby reducing tolerance stack-up and preventing contamination of PCB components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple sets of electrical pins are coupled on a single PCB, then the quantity of electrical connections is increased, but the alignment precision deteriorates due to increased tolerance stack-up
Solution Approach 1:
The patent divides the connector into separate components: the PCB assembly with electrical pins and the separate connector housing with bay. This segmentation allows each component to be manufactured and assembled independently, eliminating the tolerance stack-up that would occur if multiple pins were rigidly coupled on a single PCB. The separate connector housing can then be precisely aligned and secured to the bay using the alignment structure.
Solution Approach 2:
The patent introduces an alignment structure as an intermediary mechanism between the connector insert and the bay. This alignment structure includes alignment features that interface between the two components to ensure precise positioning. The intermediary alignment structure transfers and maintains precise alignment without being subject to the cumulative tolerances of multiple pinned connections on a single rigid PCB.
2Manufacturing precision
If traditional alignment methods are used, then the device complexity is reduced, but the alignment precision deteriorates leading to potential misalignment
Solution Approach 1:
The alignment structure incorporates pre-formed alignment features on both the connector insert and the bay housing. These alignment features are built into the components during manufacturing, so that when the connector is assembled into the housing, the alignment occurs automatically without requiring additional adjustment or complex alignment procedures. The alignment features are preliminarily positioned to guide precise placement.
Solution Approach 2:
The alignment structure is designed to be self-aligning through complementary geometric features on the connector insert and bay housing. The alignment features automatically engage and position the connector correctly within the bay during assembly, eliminating the need for external alignment tools or complex adjustment mechanisms. The system serves its own alignment function through its inherent geometric design.
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 solution ensures precise alignment of electrical pins with their corresponding bays, facilitating correct connections, reducing the risk of misalignment, and maintaining the integrity of electronic components by preventing contamination.
Implementation Method 1
The housing alignment structure interfaces with the insert alignment structure to secure the connector insert and presses centrally against the connector insert to align the set of electrical pins to the bay
Data Source
AI summary
Systems, methods, and other embodiments described herein relate to aligning a connector insert, including electrical pins, relative to a bay that receives a wire harness. In one embodiment, an electronic system includes a connector insert that includes a set of electrical pins extending through a substrate and an insert alignment structure. The electronic system also includes a housing that includes a bay to receive a wire harness, a slot within the bay to receive the connector insert, and a housing alignment structure adjacent to the slot. The housing alignment structure interfaces with the insert alignment structure to secure the connector insert and presses centrally against the connector insert to align the set of electrical pins to the bay.