Edgecard Connector Common-End Datum Alignment
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Solution Overview
Problem
Manufacturing tolerances limit the ability to achieve small pad pitches in edgecards and edgecard connectors, leading to misalignment issues that result in loss of contact or shorting, which can be costly to address with tighter tolerances.
Innovation Solution
The implementation of a biasing mechanism within the edgecard connector that aligns the edgecard by pushing it towards one edge, using features like cantilevered beams or dimples, to ensure proper contact alignment without requiring center alignment, thus reducing manufacturing costs and tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manufacturing tolerances are tightened to achieve small pad pitches, then alignment precision between pads and contacts is improved, but manufacturing cost increases
Solution Approach 1:
The connector body is designed with an asymmetric datum structure consisting of a first datum portion at one end and a second datum portion at the other end, replacing the traditional symmetric center-alignment approach. This asymmetric design allows the edgecard to be positioned with higher precision relative to the contacts without requiring tighter manufacturing tolerances on the pad pitch itself, thereby reducing manufacturing costs while maintaining alignment precision.
2Productivity
If pad pitch is reduced to increase contact density, then productivity is improved, but misalignment between pads and contacts worsens
Solution Approach 1:
Instead of relying solely on precise control of the pad pitch dimension, the invention introduces a new dimensional reference system using the first and second datum portions at the ends of the connector body. This creates a separate alignment dimension that is independent of the pad pitch, allowing small pad pitches for high contact density while maintaining alignment precision through the end-datum reference.
3Ease of operation
If float is centered to allow edgecard movement, then ease of operation is improved, but misalignment between pads and contacts increases
Solution Approach 1:
The first and second datum portions are designed to engage the edgecard during the insertion process itself, performing the alignment action preliminarily as the edgecard is being inserted. This preliminary alignment action occurs automatically during insertion, maintaining both ease of operation and alignment precision without requiring post-insertion adjustment or complex centering mechanisms.
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 allows for smaller pad pitches while minimizing misalignment issues, reducing manufacturing costs and ensuring reliable contact engagement between edgecard contacts and pads, and preventing permanent misalignment or damage.
Implementation Method 1
a biasing mechanism arranged at the first end to align the substrate as the substrate is inserted into the slot
Implementation Method 2
using features like cantilevered beams or dimples, to ensure proper contact alignment
Data Source
AI summary
A connector includes a body, a slot within the body configured to receive a substrate and including a first end and a second end, contacts arranged along the slot between the first end and the second end, and a biasing mechanism arranged at the first end to align the substrate as the substrate is inserted into the slot so that substrate is in contact with the second end when the substrate is fully inserted into the slot.