Edge Card Connector Assembly Solderless PCB Interface
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Solution Overview
Problem
The existing methods for connecting circuitry on printed circuit boards are labor-intensive and costly, requiring expensive materials and time-consuming soldering processes, especially when PCBs need to be removed or replaced.
Innovation Solution
An edge card connector assembly with a housing having card-side and harness-side portions, featuring resilient electrical contacting members that allow for secure, solderless connections between a printed circuit board and a cable, using a walled chamber with slots to accommodate the PCB and exert holding pressure through upper and lower contacting members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect wires and connectors to PCB, then connection reliability is improved, but assembly time and labor cost increase
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical bonding) with a mechanical insertion system. The PCB edge is inserted into a connector housing where resilient contacting members automatically engage with contact pads on the PCB edge, establishing electrical connections through mechanical force rather than soldering. This eliminates the need for soldering equipment and reduces assembly time while maintaining reliable electrical contact.
Solution Approach 2:
The connector incorporates resilient contacting members that automatically engage with the PCB contact pads upon insertion. The spring-loaded design allows the contacting members to self-adjust and make reliable electrical contact without requiring manual soldering or additional assembly steps. The system serves itself by using the insertion action to simultaneously position and electrically connect the PCB.
2Strength
If soldering equipment and special tools are used for PCB connection, then connection strength is improved, but equipment cost and complexity increase
Solution Approach 1:
The patent eliminates the need for soldering equipment by using a mechanical insertion system. The connector housing with resilient contacting members provides connection strength through mechanical engagement and spring force, replacing the thermal bonding process. This reduces equipment complexity to basic insertion tools while maintaining strong electrical connections.
Solution Approach 2:
The resilient contacting members act as intermediaries between the PCB edge and the external circuitry. These spring-loaded contacts provide the necessary mechanical force and electrical connection without requiring direct soldering between components. The intermediary mechanism simplifies the overall system by eliminating complex soldering equipment while maintaining connection integrity.
3Adaptability or versatility
If PCB needs to be removed or replaced, then adaptability is improved, but assembly time and labor cost increase due to desoldering
Solution Approach 1:
The patent divides the connection system into separable components: the PCB edge with contact pads and the connector housing with resilient contacting members. This segmentation allows the PCB to be independently inserted or removed from the connector without affecting other components. The modular design enables quick replacement of PCBs by simply withdrawing them from the housing, eliminating time-consuming desoldering operations.
Solution Approach 2:
The connector employs dynamic resilient contacting members that can flex and adapt during PCB insertion and removal. The spring-loaded design allows for easy insertion and extraction of the PCB edge while maintaining electrical contact during operation. This dynamic mechanism facilitates rapid PCB replacement without requiring desoldering tools or extensive assembly time.
4Reliability
If expensive materials and processes are used for connector assembly, then connection reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent employs simple, inexpensive materials for the connector components. The housing can be made from molded plastic, and the contacting members from spring steel or conductive plastic, replacing expensive metal connectors and soldering materials. The design accepts that individual contacting members may wear over time but provides an economical solution overall by eliminating costly materials and complex manufacturing processes while maintaining adequate reliability for the application.
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
This solution simplifies assembly, reduces labor and material costs, and enables secure, solderless connections, allowing for the use of inexpensive PCBs while maintaining reliable electrical contact.
Implementation Method 1
a plurality of resilient electrical contacting members extending through the wall and is adapted for electrical connection with the cable in the harness-side portion and with the printed circuit board in the card-side portion
Data Source
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Figure 5
AI summary
An edge card connector assembly has a harness-side portion connectable to a cable and a card-side portion adapted to receive a planar structure edgewise therein in a plane of entry. The edge card connector has a plurality of resilient electrical contacting members extending through the wall and is adapted for electrical connection with the cable in the harness-side portion and with the planar structure in the card-side portion. Upper and lower contacting members are disposed above and below the plane, respectively, such that the received planar structure impinges on the contacting members to urge the upper and lower contacting members away from the plane, and the upper and lower contacting members exert opposing holding pressure on the upper and lower surfaces of the planar structure at respective contact points.