Multi-Part Contact Carrier Assembly for Precise PCB Alignment
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Solution Overview
Problem
Existing methods for mounting electrical components on printed circuit boards suffer from rigid and coarse tolerance fields, leading to inadequate contact and mechanical instabilities, particularly in multi-pole insulating bodies, which complicates precise alignment and connection quality.
Innovation Solution
A method for producing a contact carrier with a multi-part insulating body, comprising a first and second insulating part, where contact elements are precisely arranged and held in defined positions using holding connections, allowing for a narrow tolerance range and improved mechanical and electrical connection to a printed circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rigid tolerance fields with medium or coarse degree of tolerance are used for mounting contact elements, then the assembly process is simpler, but the contact projection precision and arrangement accuracy deteriorate
Solution Approach 1:
The insulating body is divided into multiple parts (first insulating part and second insulating part) that are assembled together. This segmentation allows contact elements to be precisely positioned within each part while maintaining overall assembly flexibility, thereby achieving narrow tolerance ranges without requiring the entire assembly process to be rigidly constrained
Solution Approach 2:
Contact elements are pre-positioned and fixed in the first insulating part before the second insulating part is attached. This preliminary action ensures that contact elements achieve their defined positions with high precision early in the assembly process, while subsequent steps can proceed with greater flexibility
2Productivity
If contact elements are spaced closely to increase component density, then the productivity increases, but the risk of solder bridge formation and short circuits increases
Solution Approach 1:
The patent replaces traditional mechanical spacing constraints with a defined geometric model that calculates optimal contact element arrangements. This computational approach determines precise spacing that maximizes component density while maintaining safety distances to prevent solder bridges, thereby increasing productivity without compromising reliability
3Manufacturing precision
If a single insulating body is used for mounting contact elements, then the device structure is simpler, but the precision of contact element arrangement and alignment deteriorates
Solution Approach 1:
The insulating body is segmented into multiple parts that can be independently manufactured and assembled. This segmentation enables precise positioning of contact elements within each part using holding connections, while the modular structure maintains overall simplicity and facilitates high-precision alignment through defined geometric relationships between parts
4Ease of manufacture
If coarse tolerance fields are used for contact element positioning, then the ease of manufacture increases, but the mechanical stability and connection quality deteriorate
Solution Approach 1:
Holding connections serve as intermediaries between contact elements and the insulating body. These holding connections provide precise positioning and stable fixation of contact elements while maintaining ease of manufacture, as they enable accurate positioning without requiring extremely tight tolerances in the manufacturing process itself
Data Source
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AI summary
The invention relates to a method for producing a contact carrier (1) with at least one contact element (210, 220) for transmitting electrical energy and/or electrical signals, and with an insulating body (100; 110, 120) for receiving the at least one contact element (210, 220), wherein the contact carrier (1) is configured for connection to a printed circuit board (300), comprising: • inserting a first contact section (211, 221) of the at least one contact element (210, 220) into a first insulating part (110) of the insulating body (100) in an assembly direction (X); • forming a holding connection (211, 110) of the first contact section (211, 221) with the first insulating part (110) in a defined position; and/or holding, preferably supporting, the inserted at least one contact element (210) in a defined position in the mounting direction (X) by a holding tool;• Attaching a second insulating part (120) of the insulating body (100) to a second contact section (212, 222) of the at least one contact element (210, 220) in the mounting direction (X), and/or inserting a second insulating part (120) of the insulating body (100) for receiving a second contact section (212, 222) of the at least one contact element (210) into the first insulating part (110) in the mounting direction (X), until a defined mounting state of the contact carrier (1) for connection to the printed circuit board (300) is reached and/or formed. The method enables, above all, a more precise adjustment of the at least one contact element (210, 220), preferably of a projection (U212, U222) of the at least one contact element (210, 220). The invention further relates to a contact carrier (1) and a plug connector having a contact carrier (1).;