Coplanar Card Edge Connector for Mixed PCB Thickness
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Solution Overview
Problem
Existing card edge connectors have limited tolerance for thickness variances between circuit boards, restricting their ability to connect boards of varying thicknesses in a coplanar manner due to dimensional limitations and terminal flexibility.
Innovation Solution
The electrical connector design features a frame with parallel platforms and a housing that includes conductive terminals, allowing for screws to be inserted through threaded holes to securely connect circuit boards of different thicknesses in an edge-to-edge configuration, with ribs providing shielding and improved terminal density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional card edge connector design is used, then the structure is simple, but the tolerance for thickness variations between circuit boards is limited
Solution Approach 1:
The connector is divided into multiple functional components: a frame with first and second platforms for mounting different circuit boards, a housing containing conductive terminals, and ribs for shielding. This segmentation allows each component to be optimized independently, enabling the connector to accommodate thickness variations while maintaining structural integrity and electrical performance.
Solution Approach 2:
The connector design transitions from a single-plane mounting structure to a three-dimensional configuration with platforms at different heights and a housing that extends in multiple directions. This dimensional change allows the connector to accommodate circuit boards of different thicknesses by providing mounting surfaces at varying elevations while maintaining coplanar alignment of the connected boards.
2Adaptability or versatility
If additional separation space is provided between circuit boards, then thickness variance tolerance is improved, but the overall device size increases
Solution Approach 1:
The housing containing the conductive terminals is nested within the frame structure, and the ribs are integrated into the frame and housing. This nesting arrangement allows multiple functional elements to occupy overlapping or adjacent spaces efficiently, providing the necessary separation for thickness tolerance without proportionally increasing the overall connector volume.
Solution Approach 2:
Instead of increasing separation distance in the primary mounting direction, the design utilizes vertical dimension with platforms at different heights and three-dimensional positioning of terminals within the housing. This allows thickness variance accommodation through vertical offset rather than horizontal separation, maintaining compact overall dimensions.
3Productivity
If terminal density is increased, then electrical connection efficiency is improved, but signal interference between terminals increases
Solution Approach 1:
Ribs are strategically positioned between adjacent conductive terminals within the housing to provide localized electromagnetic shielding. This local quality enhancement allows high terminal density for improved connection efficiency while the ribs create electromagnetic barriers that prevent signal interference between neighboring terminals, addressing both requirements simultaneously.
4Reliability
If shielding structures are added between terminals, then signal integrity is improved, but device complexity increases
Solution Approach 1:
The shielding ribs are merged with the frame and housing structures rather than being separate components. The ribs extend from the frame into the housing, forming an integrated shielding system that provides signal integrity protection while avoiding the complexity of separate shielding assemblies. This merging reduces the number of discrete parts and simplifies manufacturing.
Data Source
AI summary
An electrical connector that connects circuit boards in a coplanar manner. The electrical connector includes a frame comprising a plate, and two platforms extending above the plate and substantially parallel to each other. A housing of the electrical connector holding conductive elements is coupled to the plate of the frame such that a top surface of the housing is substantially flush with top surfaces of the two platforms. The platforms of the frame have threaded holes extending therethrough such that screws can be inserted to hold one of the two platforms of the electrical connector to a first circuit board and the other one of the two platforms of the electrical connector to a second circuit board that is substantially edge aligned to the first circuit board. Such a configuration enables connecting circuit boards of various thicknesses in a coplanar manner.