Contact Array Connector Structure for Heat-Stable PCB-Flex Assembly

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Solution Overview

Problem

Conventional connectors for flexible and printed circuit boards are complex to assemble, prone to damage, and can disconnect during physical stress, requiring secure and easy connection, reliable manufacturing, and resistance to heat without warpage.

Innovation Solution

The development of connectors with an array of contacts, including surface-mount contacting portions and a shell with folded tabs, which are injection molded and designed to securely connect flexible and printed circuit boards, using materials like Liquid Crystal Polymer and conductive metals, ensuring reliable and consistent connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conventional connectors are used to connect flexible and printed circuit boards, then connections can be established, but the assembly procedure becomes complicated and component damage occurs

Engineering Contradiction:

Improveease of assemblyVSAvoidassembly procedure complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent combines the flexible circuit board connector and printed circuit board connector into a single integrated connector assembly. This merging eliminates the need for separate assembly procedures for each connector type, simplifying the overall assembly process and reducing the risk of component damage during assembly.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connector is divided into distinct functional segments including a flexible circuit board connector portion, a printed circuit board connector portion, and an interconnecting structure. This segmentation allows each portion to be optimized for its specific function while maintaining overall assembly simplicity through the integrated design.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If connectors are designed to provide many connections, then functionality increases, but the connector structure becomes more complex

Engineering Contradiction:

Improvenumber of connectionsVSAvoidconnector structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The integrated connector design allows a single connector assembly to provide multiple connection functions simultaneously - connecting to both flexible and printed circuit boards with multiple contact points. This multi-functionality increases the number of connections without proportionally increasing structural complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The connector employs a nested structure where the flexible circuit board connector portion is integrated within or alongside the printed circuit board connector portion. This nesting arrangement allows multiple connection functions to be compactly organized, increasing connectivity while controlling structural complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Productivity

If connectors are exposed to heat during assembly, then manufacturing process continues, but warpage occurs

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidconnector warpage

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The patent selects materials with appropriate thermal properties and designs the connector structure with controlled thermal expansion characteristics. This allows the connector to withstand heat exposure during manufacturing processes without excessive warpage, maintaining manufacturing efficiency while preserving dimensional stability.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If connectors are designed for secure connection, then connection reliability improves, but manufacturing complexity increases

Engineering Contradiction:

Improveconnection securityVSAvoidmanufacturing simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The connector incorporates pre-formed interlocking features and alignment structures that are created during the manufacturing process. These preliminary structural actions ensure secure connection upon assembly without requiring complex additional manufacturing steps or procedures.

Inventive Principle:

Principle #10Preliminary action

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 connectors provide a secure, reliable, and easy-to-assemble connection between flexible and printed circuit boards, maintaining integrity under physical stress and heat exposure without excessive warpage, facilitating efficient electronic device manufacturing and operation.

Implementation Method 1

can be exposed to heat during assembly of an electronic device without excessive warpage

Methodology Applied

Scientific EffectThermal stability: Thermal Expansion

Implementation Method 2

tabs on the shell can be folded or bent under the shell to form the connector

Methodology Applied

Scientific EffectMechanical fastening: Mechanical Fastener

Implementation Method 3

which are injection molded and designed to securely connect flexible and printed circuit boards

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS20240055788A1Connector having contact array

Publication Date: 2024.02.15 APPLE INC

AI summary

Connectors that provide a large number of connections between a flexible circuit board and a printed circuit board, can easily and securely connect the flexible circuit board to the printed circuit board, are readily manufactured, and can be used in an assembly of an electronic device without excessive warpage.