Elastic Connecting Element for Tolerance-Compensated PCB Assembly
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Solution Overview
Problem
Conventional circuit board connections for high-frequency technology are inadequate due to high manufacturing effort, costs, and limited tolerance compensation, leading to poor electrical and mechanical connectivity.
Innovation Solution
A connecting element with a carrier body and separate elastic contact elements that can be positioned between two electrical assemblies for direct electrical and optional mechanical connection, allowing for tolerance compensation and reduced overall height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional multi-part PCB connectors are used, then electrical connection between assemblies is achieved, but manufacturing effort and costs increase significantly
Solution Approach 1:
The patent combines multiple separate connector parts into a single integrated connecting element. The connecting element comprises a housing, a printed circuit board, and electrical contacts that are all merged into one component, eliminating the need for separate coaxial connectors and adapters. This reduces manufacturing steps and assembly complexity while maintaining reliable electrical connection for high-frequency signals.
2Reliability
If conventional multi-part connectors are used, then electrical connection is established, but manufacturing precision requirements become very stringent
Solution Approach 1:
By integrating the housing, circuit board, and electrical contacts into a single connecting element, the patent eliminates cumulative tolerance errors that occur when multiple parts are assembled together. The printed circuit board is directly formed as part of the housing structure, ensuring precise alignment and positioning of electrical contacts without requiring stringent tolerance control during assembly of separate components.
3Reliability
If conventional multi-part connectors are used, then electrical connection is achieved, but overall assembly height increases
Solution Approach 1:
The patent integrates the circuit board and electrical contacts directly into the housing structure, eliminating the need for separate connector bodies and mounting fixtures. This integration significantly reduces the overall height of the connecting element compared to conventional multi-part connectors, while maintaining reliable electrical connection capability.
4Ease of manufacture
If simplified one-piece elastic block connectors are used, then manufacturing effort is reduced, but tolerance compensation capability is limited
Solution Approach 1:
The patent incorporates elastic elements within the integrated connecting structure that provide dynamic adaptation capability. These elastic components allow the connecting element to compensate for misalignments and tolerances between assembled parts, enabling the rigid housing to adapt to variations in assembly positioning while maintaining reliable electrical connection.
5Ease of manufacture
If simplified elastic block connectors are used, then manufacturing is easier, but electrical properties and mechanical connectability deteriorate
Solution Approach 1:
The patent uses a composite structure combining a rigid housing material with a printed circuit board and elastic elements. The housing provides mechanical strength and stability, the printed circuit board ensures reliable electrical transmission for high-frequency signals, and the elastic elements provide adaptability. This composite approach maintains superior electrical properties while enabling easier manufacturing compared to conventional connectors.
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 enables a low-effort, low-height connection with improved tolerance compensation and suitable electrical properties for high-frequency applications, reducing manufacturing complexity and costs while maintaining robust signal transmission.
Implementation Method 1
The contact elements are each designed to be elastic at least in sections along a contact direction running from the first contact region to the second contact region in order to compensate for a tolerance-related spacing offset between the two electrical assemblies
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a connecting element (1) for electrically connecting a first electrical assembly (3) to a second electrical assembly (4), comprising a carrier body (5) with a first contact side (6) and an opposing, second contact side (7). The connecting element (1) also has a plurality of separate electrical contact elements (8a, 8b), each having a first contact area (8.1) for electrically contacting the first electrical assembly (3) and a second contact area (8.2) for electrically contacting the second electrical assembly (4), wherein the first contact area (8.1) and the second contact area (8.2) are electrically connected to each other, and wherein the contact elements (8a, 8b) are each connected to the separate carrier body (5) such that the first contact area (8.1) extends from the first contact side (6) and the second contact area (8.2) extends from the second contact side (6).2) are electrically contactable starting from the second contact side (7). The contact elements (8a, 8b) are each designed to be at least partially elastic along a contact direction (K) extending from the first contact area (8.1) to the second contact area (8.2) in order to compensate for a tolerance-related distance offset between the two electrical assemblies (3, 4).