Eye-of-the-Needle Pin With Transitional Walls
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Solution Overview
Problem
As electronic systems become smaller and signal rates increase, the demand for smaller electrical vias in printed circuits leads to reduced size EON pins that lack structural rigidity, causing buckling and poor electrical connections when inserted into vias.
Innovation Solution
The design of EON pins with a neck segment featuring transitional walls with rounded, chamfered, or filleted corners, increasing the width and thickness to enhance structural rigidity, allowing them to be inserted into smaller vias without buckling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the EON pin size is reduced to fit smaller electrical vias, then the via density and signal rate are improved, but the structural rigidity of the EON pin deteriorates causing buckling
Solution Approach 1:
The EON pin is designed with non-uniform cross-sectional dimensions along its length. The intermediate section has reduced width and thickness compared to the base section, creating localized variations in structural properties. This allows the pin to have sufficient rigidity at the base for stable mounting while being flexible enough in the intermediate section to navigate via entry without buckling, thus resolving the contradiction between overall size reduction and localized structural rigidity.
Solution Approach 2:
The EON pin is divided into distinct sections with different geometric characteristics: a base section with larger dimensions for stability, an intermediate section with reduced dimensions for flexibility during insertion, and a tip section for electrical contact. This segmentation allows each part to fulfill different functional requirements, enabling the pin to maintain rigidity where needed while reducing size where flexibility is required, thereby solving the buckling problem in smaller vias.
2Quantity of substance
If the EON pin size is reduced to fit smaller electrical vias, then the via density is improved, but the insertion reliability deteriorates due to buckling
Solution Approach 1:
The EON pin features localized geometric variations along its length, with the intermediate section having reduced cross-sectional dimensions compared to the base. This creates a flexible zone that can bend and conform during insertion into small vias, preventing buckling and ensuring reliable electrical connection, thus maintaining insertion reliability while enabling higher via density.
Solution Approach 2:
The pin structure is segmented into functional zones: a rigid base for stable mounting, a flexible intermediate section for safe navigation through via entry, and a contact tip for electrical connection. This segmentation ensures that each section performs its specific function optimally, preventing insertion failures and maintaining reliability even as via density increases with smaller via sizes.
Data Source
AI summary
An electrical contact includes a base and an eye-of-the needle (EON) pin extending a length outwardly from the base to a tip. The EON pin is configured to be received within an electrical via. The EON pin includes a neck segment that extends outwardly from the base, a tip segment that includes the tip, and a compliant segment that extends from the neck segment to the tip segment. The neck segment has opposite end walls and opposite side walls that extend between the end walls. The end walls are connected to the side walls at corresponding transitional walls that interconnect spaced-apart edges of the corresponding end and side walls.