Floating Circuit Board Carrier Alignment Mechanism
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Solution Overview
Problem
The assembly of electronic devices is challenging due to the difficulty in achieving precise alignment between modular components and circuit boards, particularly when external modular components need to be connected to internal components within a device housing, often requiring cumbersome trial-and-error methods.
Innovation Solution
A floating circuit board carrier is used to mount the circuit board to an adaptor plate, allowing the circuit board to 'float' within the housing, with posts or pins on the modular component aligning with clearance holes, and half-holes on the circuit board ensuring proper orientation and alignment, simplifying the connection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a ribbon cable is used to allow free movement of electrical connectors, then connection between internal electronic component and external modular component becomes possible, but the modular component must be held near the device housing during connection which makes assembly awkward and difficult
Solution Approach 1:
The circuit board is pre-mounted on the floating carrier at a predetermined position and orientation relative to the housing. The carrier is positioned in advance so that when the modular component is mounted, the connectors are already aligned for engagement, eliminating the need to hold and position the modular component manually during connection.
2Adaptability or versatility
If connectors are allowed to move freely during assembly, then connection flexibility is improved, but precise alignment between connectors becomes difficult to achieve
Solution Approach 1:
The floating carrier is pre-positioned on the housing with the circuit board mounted at a predetermined location. The carrier's position is fixed relative to the housing before assembly, establishing precise alignment references that guide the modular component into correct alignment with the connectors during assembly.
Solution Approach 2:
The floating carrier acts as an intermediary mounting structure between the housing and the circuit board. It provides a stable, pre-aligned platform that maintains the circuit board at the correct position and orientation, serving as a reference for aligning the modular component's connectors with the circuit board connectors.
3Ease of operation
If trial-and-error approach is used to achieve proper connection, then alignment flexibility is maintained, but assembly time and complexity increase
Solution Approach 1:
The circuit board is pre-mounted on the floating carrier at the correct position and orientation before the modular component is installed. This preliminary positioning establishes accurate alignment references that guide the assembly process, eliminating the need for trial-and-error positioning and reducing assembly time.
Data Source
AI summary
Systems and methods are provided that facilitate accurate alignment of internal and external electronic components during assembly of an electronic device such that proper engagement of mating electrical connectors on the respective components is assured. To this end, a floating circuit board carrier mounts to an adaptor plate comprising a surface of the device housing and positions a circuit board such that it “floats” within the device housing. A modular component having posts molded or attached thereto is mounted to the adaptor plate such that the posts pass through clearance holes in the adaptor plate as well as through notches in the circuit board, thereby effecting proper relative alignment of the circuit board and the modular component as electrical connectors on the respective components are engaged.