Floating Conductor Structure for Vibration-Tolerant PCB Connectors
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Solution Overview
Problem
Conventional board-to-board connectors fail to maintain stable electrical connections in complex and high-frequency environments, leading to data transmission failures and potential damage due to offset centers, high vibrations, and extreme temperatures, posing safety risks.
Innovation Solution
A conductor structure with a weld leg portion, intermediate curved portion, and sliding insertion portion, featuring a back-bending and curved design with interference regions, allowing for flexible fixation and vibration damping, enabling effective connection and conduction even with offset centers and varying temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional board-to-board connector is used, then the connector structure is simple, but the electrical connection becomes unstable in high-vibration and extreme temperature environments
Solution Approach 1:
The conductor is designed with a curved portion that can dynamically deform to compensate for misalignment and vibration. The curved shape allows the conductor to flex and adapt to positional variations between plug and socket, maintaining stable electrical connection in high-vibration environments without requiring complex active control mechanisms.
Solution Approach 2:
The conductor's geometric parameters are optimized by introducing a curved portion with specific radius and angle. This parameter change transforms the rigid straight conductor into a flexible curved one, enabling it to absorb vibration and temperature-induced expansion/contraction while maintaining reliable electrical contact.
2Speed
If the connector is designed for high transmission speed, then the signal transmission performance improves, but the connector becomes more sensitive to center offset and vibration
Solution Approach 1:
The curved portion of the conductor provides dynamic compensation for center offset up to ±0.5mm. As the plug and socket align, the curved conductor flexes to accommodate the offset, ensuring that high-speed signals maintain stable transmission without being disrupted by manufacturing tolerances or assembly variations.
Solution Approach 2:
The curved conductor structure预先 (in advance) absorbs potential misalignment and vibration stresses before they can affect the electrical connection. By designing the conductor with built-in flexibility, the system preemptively compensates for expected environmental variations, protecting the high-speed signal transmission from disruption.
3Strength
If the conductor material is made more rigid to withstand vibration, then the vibration resistance improves, but the ability to accommodate center offset decreases
Solution Approach 1:
The conductor is segmented into different functional portions: a rigid portion for structural support and vibration resistance, and a curved flexible portion for accommodating offset. This segmentation allows each portion to optimize its properties independently, combining the benefits of both rigidity and flexibility in a single conductor design.
Solution Approach 2:
Different portions of the conductor have different mechanical properties. The curved portion is designed with local flexibility to accommodate offset, while other portions maintain sufficient rigidity for vibration resistance. This local differentiation of material or geometric properties allows the conductor to simultaneously satisfy conflicting requirements.
Data Source
AI summary
A welding foot portion of an conductor structure is welded with a circuit board; a back bending structure and a bending structure which are connected to each other are formed at a middle bending portion of the conductor structure; a first interference area and a second interference area are provided; a sliding insertion portion of the conductor structure is configured to be connected to a plug conductor of a plug connector; the back bending structure and the bending structure of the conductor structure are configured to be exposed between a socket lower shell and a socket upper shell in a floating mode when the first interference area is in close contact with the socket lower shell and the second interference area is in close contract with the socket upper shell.