Contact Array Connector Structure for Low-Warpage PCB Assembly

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Solution Overview

Problem

Conventional connectors for flexible and printed circuit boards are prone to damage during assembly, require complex assembly procedures, and can experience inadvertent disconnections due to physical stress, while also being susceptible to warpage during heat exposure, which complicates manufacturing and reliability.

Innovation Solution

The development of connectors with an array of contacts, including surface-mount contacting portions and a frame with slats and tabs, that are injection molded and designed to securely connect flexible and printed circuit boards, allowing for easy mating and disconnection, and are manufactured using materials like Liquid Crystal Polymer to withstand heat without excessive warpage.

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 assemblyVSAvoidcomponent damage

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent combines the flexible circuit board connector and rigid circuit board connector into a single integrated connector assembly. The housing unifies both connector types, and the contact array provides simultaneous electrical connections to both board types, eliminating the need for separate assembly procedures and reducing component damage risk.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connector is segmented into distinct functional regions: a first recess for the flexible circuit board, a second recess for the rigid circuit board, and a contact array with differentiated contacting portions. Each segment is optimized for its specific function, allowing easy mating with respective board types while maintaining reliability.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If connectors are designed to provide many connections between boards, then functionality increases, but assembly complexity and damage risk increase

Engineering Contradiction:

Improvenumber of connectionsVSAvoidassembly procedure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Multiple connection functions are merged into a single connector housing. The contact array integrates both flexible board contacts and rigid board contacts in one unified structure, providing numerous connections simultaneously without requiring multiple separate assembly operations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single connector housing serves multiple functions: it houses contacts for flexible circuit boards, houses contacts for rigid circuit boards, provides mechanical support, and enables simultaneous mating with both board types. This multi-functionality reduces overall system complexity despite providing many connections.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

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

Engineering Contradiction:

Improvemanufacturing continuityVSAvoidconnector warpage

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The housing material parameters are specifically selected to resist thermal warpage. By choosing materials with appropriate thermal expansion coefficients and structural stability, the connector maintains its dimensional precision throughout the heat exposure of manufacturing processes like reflow soldering.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The housing may utilize composite material structures that combine materials with complementary thermal properties. This composite construction provides thermal stability and resistance to warpage during heat-based manufacturing processes while maintaining manufacturing productivity.

Inventive Principle:

Principle #40Composite materials

4Adaptability or versatility

If connectors are subjected to physical stress during device movement, then portability is maintained, but inadvertent disconnections occur

Engineering Contradiction:

Improvedevice portabilityVSAvoidconnection stability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The contact array features flexible contacting portions that can bend and deform elastically in response to physical stress. This curvature and flexibility allow the contacts to absorb mechanical shocks and stresses during device movement while maintaining continuous electrical connection, preventing inadvertent disconnections.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The contacting portions are designed with flexible characteristics, allowing them to deform under stress and return to their original position. This flexibility, combined with the secure housing structure, maintains connection stability during device portability and movement while accommodating physical stress.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS11799225B2Connector having contact array

Publication Date: 2023.10.24 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.