Floating Z-Stacked PCB Connector for Tolerance Misalignment
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Solution Overview
Problem
Existing information handling systems face issues with varying distances between PCBs due to manufacturing tolerances, leading to skew-angles, incomplete thermal and electrical contacts, and excessive stress, necessitating rework when connector elements are damaged.
Innovation Solution
A flexible connector apparatus with z-axis compression connectors and a floating connector mount that adapts to varying distances, using screw and bolster arrangements to secure compression connectors and a flexible block to maintain alignment, allowing for adjustable mechanical and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid connectors are used to connect PCBs, then mechanical strength is improved, but manufacturing precision deteriorates due to inability to accommodate distance variations
Solution Approach 1:
The connector mount is designed to be flexible rather than rigid, allowing it to dynamically adapt to distance variations between PCBs. The flexible block enables the connector to change its configuration based on the actual gap, maintaining both mechanical strength and manufacturing precision accommodation.
Solution Approach 2:
The connector apparatus changes its physical parameters (distance, angle) by using a flexible block that can compress and deform. This allows the connector to adjust to different PCB spacing while maintaining reliable electrical and thermal contact, resolving the contradiction between fixed strength requirements and variable manufacturing tolerances.
2Device complexity
If fixed-distance connectors are used, then structural simplicity is improved, but reliability deteriorates due to skew-angles and incomplete contacts
Solution Approach 1:
The flexible connector mount transitions from a static, fixed-distance design to a dynamic structure that can adapt its shape and position. This dynamic capability ensures reliable electrical and thermal contact despite variations in PCB spacing, preventing skew-angles and incomplete contacts while adding minimal complexity.
Solution Approach 2:
The connector incorporates a flexible block that acts as a compliant element, allowing the connector to bend and conform to the actual distance between PCBs. This flexibility ensures consistent contact pressure and alignment, improving reliability without requiring complex adjustment mechanisms.
3Manufacturing precision
If compression connectors are used, then electrical connection quality is improved, but stress on PCBs increases
Solution Approach 1:
The flexible block serves as an intermediary element between the compression connectors and the PCBs. It absorbs and distributes the compression forces, providing consistent electrical contact quality while reducing peak stress on the PCB structures through its compliant nature.
Data Source
AI summary
A connector apparatus is provided for electrically connecting and mechanically affixing a first PCB to a second PCB. The connector apparatus includes a flex connector and a connector mount. The flex connector has a first compression connector to provide electrical connections to the first PCB, a second compression connector to provide electrical connections to the second PCB, and a flex cable coupled to the first and second compression connectors. The connector mount is coupled between the first and second compression connectors.