Deformable Tolerance Compensation in Electrical Plug Connectors
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Solution Overview
Problem
Electrical plug connectors face challenges in tolerance compensation between plug parts soldered to a circuit board and their insulating bodies, leading to misalignment and potential damage due to manufacturing and soldering tolerances, especially in surface-mountable components.
Innovation Solution
Incorporating a tolerance compensation part with a deformable geometry, such as S-shaped or spiral contours, to allow for flexible displacement of plug connection elements relative to solder connection elements, enabling alignment without mechanical stress on soldered joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the insulating body is positioned exactly as specified in the design, then the alignment precision is improved, but the manufacturing complexity and cost increase due to the need for precise housing parts with chambers or passages
Solution Approach 1:
The patent applies the dynamics principle by making the plug part itself deformable through an integrated tolerance compensation part, allowing it to adapt its position dynamically after soldering. This eliminates the need for complex housing parts with precise chambers or passages, as the plug part can self-adjust to accommodate manufacturing tolerances in the circuit board and housing.
2Adaptability or versatility
If the plug parts are held in floating condition in the insulating body, then the adaptability to misalignment is improved, but the mechanical stress on soldered connections increases and may cause damage
Solution Approach 1:
The patent applies parameter changes by modifying the physical state of the plug part through controlled deformation. The tolerance compensation part is designed with specific geometric contours (S-shaped, spiral, or wavelike) that allow it to deform elastically within a defined range, changing its shape parameter to absorb misalignment while maintaining stable mechanical connections.
3Stability of the object's composition
If a rigid connection is used between plug connection element and solder connection element, then the structural stability is improved, but the tolerance compensation capability is reduced
Solution Approach 1:
The patent applies segmentation by dividing the plug part into functionally distinct segments: a rigid portion for stable electrical connection and a deformable tolerance compensation part for absorbing misalignment. This segmentation allows each segment to perform its specific function optimally while working together as an integrated unit.
Solution Approach 2:
The patent applies local quality by making only the specific tolerance compensation part deformable, while keeping the rest of the plug part rigid. The deformable section has specific geometric contours designed for elasticity, localized to where tolerance compensation is needed, rather than making the entire plug part flexible.
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 solution effectively compensates for manufacturing and soldering tolerances, ensuring precise alignment and reducing mechanical stress on soldered connections, thereby enhancing the durability and reliability of plug connectors.
Implementation Method 1
a tolerance compensation part (7) with a deformable geometry, such as S-shaped or spiral contours, to allow for flexible displacement of plug connection elements relative to solder connection elements
Data Source
AI summary
An electrical plug connector with an insulating body that holds at least one metallic plug part that comprises at least one solder connection element that can be soldered to a circuit board, and at least one plug connection element for a matching plug part, both of which are connected with each other via a central piece of the plug connection element. The solder connection element may be connected via a tolerance compensation part with the central piece of the plug part, or directly with the plug connection element, in such a way that, relative to the position of the solder connection element—with the solder connection element soldered to the circuit board—the position of the plug connection element can be changed in any direction, parallel to the plane of the circuit board. In addition, the invention relates to a plug connector assembly.