Disposable Electrical Connector With Enclosed PCB
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Solution Overview
Problem
Conventional high density electrical connectors require an exposed printed circuit board, posing reliability and safety concerns due to exposed conductive contacts, and are not scalable or cost-effective for complex systems.
Innovation Solution
A mated pair electrical connector design utilizing a printed circuit board within a disposable housing, allowing for high density and low-cost connections while providing protection against contaminants and electrical interference, with a plug and receptacle configuration that ensures secure and quick coupling through grooves and protrusions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If card edge connectors with exposed printed circuit board are used, then high density electrical connections can be achieved, but reliability and safety deteriorate due to exposed conductive contacts
Solution Approach 1:
The patent employs a disposable connector housing that integrates the printed circuit board within an enclosed structure. This disposable approach allows for high-density connections while eliminating the need for exposed conductors, as the entire connector can be replaced rather than maintained, ensuring safety without compromising connection density
Solution Approach 2:
The connector design integrates multiple functions into a single enclosed housing: the printed circuit board provides electrical connections, the housing provides structural support and environmental protection, and the integrated design eliminates the need for separate exposed conductor elements. This multi-functionality achieves high-density connections while maintaining safety through enclosure
2Quantity of substance
If card edge connectors are designed for specific circuit boards, then electrical connection can be achieved, but manufacturing cost increases due to lack of scalability
Solution Approach 1:
The connector housing is designed as a universal platform that can accommodate different printed circuit board configurations. The standardized enclosed housing structure allows the same basic design to serve multiple applications, enabling economies of scale in manufacturing while maintaining the ability to provide high-density electrical connections for various systems
3Quantity of substance
If exposed conductive surfaces are used for electrical connection, then electrical coupling is achieved, but contamination and degradation increase over time
Solution Approach 1:
The patent utilizes an enclosed housing structure that acts as a protective shell around the printed circuit board and conductive elements. This enclosure prevents direct exposure to environmental contaminants while maintaining electrical functionality through sealed interfaces, thereby eliminating contamination and degradation issues associated with exposed conductors
Data Source
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AI summary
An electrical connector comprising a first housing defining a cavity therein, a first printed circuit board disposed in the cavity of the first housing, a contact coupled with the first printed circuit board, a disposable second housing defining a cavity therein, and a second printed circuit board disposed in the cavity of the second housing, the second printed circuit board having a contact pad positioned on a surface of the second printed circuit board, the contact pad of the second printed circuit board configured to engage with the contact when the first housing and the second housing are mated together.