Connector Net Structure for Warped PCB Contact Stability
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Solution Overview
Problem
Conventional connectors face challenges in maintaining contact stability due to warping of printed boards, which reduces the effectiveness of electrical connections and mechanical strength, especially when the pitch between elastic conductors is narrowed, making it difficult to perform resin molding with high accuracy.
Innovation Solution
A connector design featuring an insulating holder with parallel linear insulating portions and holding portions that sandwich contact members with linear cores and conductive paths, forming a net structure that allows for elastic deformation and improved contact stability, using flexible wires and resin tapes for enhanced flexibility and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the pitch between elastic conductors is narrowed by reducing partition wall thickness, then the density of electrical connections is improved, but the strength and moldability of the insulating plate deteriorates
Solution Approach 1:
The insulating plate uses a composite structure combining resin material with reinforcing ribs. The ribs are integrally formed with the resin plate, creating a composite structure that provides both electrical insulation and mechanical strength. This allows narrow pitch between conductors while maintaining partition wall strength through the rib reinforcement.
Solution Approach 2:
The insulating plate is segmented into multiple regions with reinforcing ribs strategically positioned between adjacent elastic conductors. These ribs divide the plate into structured sections, providing localized strength support where needed while maintaining the overall integrity of the insulating plate even with reduced partition wall thickness.
2Manufacturing precision
If the partition wall thickness is reduced to achieve narrower pitch, then the arrangement density of conductors is improved, but the resin molding process becomes more difficult
Solution Approach 1:
The reinforcing ribs create a composite structure within the resin plate that provides structural support during molding. The ribs act as internal scaffolding that maintains mold cavity integrity, enabling accurate resin injection and molding even when partition walls are thin, thus facilitating the resin molding process rather than hindering it.
Solution Approach 2:
The reinforcing ribs provide localized structural enhancement only where needed between conductors, rather than uniformly thickening the entire plate. This localized quality improvement allows thin partition walls for narrow pitch while maintaining overall moldability and manufacturing feasibility through strategic reinforcement only at critical stress points.
3Adaptability or versatility
If printed boards warp during assembly, then mechanical flexibility is required, but electrical connection stability deteriorates
Solution Approach 1:
The elastic conductors are designed with inherent elasticity, allowing them to dynamically deform and adapt to warpage in the printed boards. The conductors can bend and flex as needed while maintaining continuous electrical contact, providing both the flexibility to accommodate deformation and the stability to maintain reliable electrical connections throughout the deformation range.
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 connector improves contact stability by allowing the net structure to deform with warping printed boards, maintaining electrical connections and mechanical strength while ensuring accurate positioning of conductive paths, even when the pitch is narrowed.
Implementation Method 1
a plurality of contact members (3) which are sandwiched between the first object to be connected (21, 22) and the second object to be connected (21, 22) and are elastically deformed therebetween
Data Source
AI summary
A connector capable of improving the contact stability. Linear cores of contact members and wires of an insulating holder are weaved to thereby form a net. Conductive path portions of the contact members are disposed such that they extend through a mesh.