Header Connector Press-Fit Compliant Pins Assembly
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Solution Overview
Problem
Conventional header connectors for automotive applications are costly and time-consuming due to the need for soldering signal and ground contacts to printed circuit boards, which complicates assembly and increases costs.
Innovation Solution
A header connector design featuring a dielectric housing with signal contact channels and a ground shield channel, where the ground shield provides electrical shielding and is configured to be mated with the mating connector, and a seal pocket for environmental sealing, eliminating the need for soldering by using a press-fit mechanism with compliant pins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect signal and ground contacts to the printed circuit board, then the connector can withstand harsh automotive environments including vibration, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical joining method) with a mechanical press-fit mechanism. The compliant pins are inserted into receptacles on the printed circuit board and secured through mechanical interference fit and retention features, eliminating the need for soldering while maintaining connection reliability under vibration and harsh conditions.
Solution Approach 2:
The compliant pins incorporate built-in retention features and interference fit mechanisms that automatically secure the contacts to the board during insertion. The design includes self-aligning and self-retaining characteristics that eliminate the need for additional soldering steps or external fastening operations.
2Reliability
If soldering is used to connect signal and ground contacts to the printed circuit board, then the connector can withstand harsh automotive environments including vibration, but assembly time and cost increase
Solution Approach 1:
The patent replaces the multi-step soldering process with a single-step mechanical press-fit operation. The compliant pins are simply inserted into the board receptacles where they automatically secure through interference fit and retention features, dramatically reducing assembly time while maintaining reliability in vibration and harsh environments.
Solution Approach 2:
The compliant pins are pre-formed with retention features and interference fit geometries during manufacturing. This preliminary preparation allows the pins to self-secure to the board upon insertion, eliminating the need for time-consuming soldering operations during final assembly.
3Productivity
If a press-fit mechanism with compliant pins is used instead of soldering, then assembly time and costs are reduced, but the challenge is to maintain reliability in harsh automotive environments
Solution Approach 1:
The patent applies different local qualities to different parts of the compliant pin structure. The pin features hardened interference fit zones for secure mechanical attachment, flexible intermediate sections for compliance and stress absorption, and retention features for positive locking. This localized differentiation ensures reliability in harsh environments while maintaining ease of assembly.
Solution Approach 2:
The compliant pins incorporate dynamic characteristics with flexible sections that allow movement and compliance under thermal expansion, vibration, and mechanical stress. This dynamic behavior enables the mechanical press-fit connection to maintain reliability in harsh automotive environments without requiring soldering.
4Reliability
If conventional header connectors are used, then electrical connectivity is achieved, but additional soldering steps are required that complicate the assembly process
Solution Approach 1:
The patent merges the electrical contact function and the mechanical retention function into a single integrated compliant pin component. The pin simultaneously provides electrical connectivity and mechanical securing through its integrated structure with built-in retention features, eliminating the need for separate soldering operations and simplifying the manufacturing process.
Solution Approach 2:
The compliant pin serves multiple functions: it provides electrical signal transmission, mechanical support, stress absorption through compliance, and self-retention through integrated locking features. This multi-functionality eliminates the need for separate soldering steps and simplifies the overall assembly process while maintaining reliable electrical connectivity.
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 reduces assembly time and costs by using a press-fit mechanism with compliant pins and a seal pocket for environmental sealing, while maintaining electrical integrity and shielding for high-speed data signaling in harsh automotive environments.
Implementation Method 1
a ground shield providing electrical shielding for the signal contacts
Implementation Method 2
a seal pocket for environmental sealing
Data Source
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AI summary
A header connector (102) includes a header housing (110) having a mating end (120) and a mounting end (122) mounted to a circuit board (106). The header housing has a cavity (128) at the mating end and a flange (140) forming a seal pocket (144) with a seal (116). A signal contact (112) is received in a signal contact channel (160) of the header housing having a mounting end having a compliant pin (206) configured to be press-fit into a plated via of the circuit board. A ground shield (114) is received in a ground shield channel (162) of the header housing providing electrical shielding for the signal contact. The ground shield has a compliant pin (306) configured to be press-fit into a plated via of the circuit board.