Helical Spring Backplane Connector for Reliable PCB Contact
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Solution Overview
Problem
Existing electrical connectors for signal-level connections often fail to maintain sufficient contact force, leading to oxidation and corrosion due to environmental factors, which can interfere with the electrical connection between printed circuit boards oriented at right or oblique angles.
Innovation Solution
A helical spring connector is used to create continuous electrical connections between printed circuit boards, where the helical spring is threaded through plated holes in one board and soldered to ensure contact with conductive pads on another board, providing necessary contact pressure to prevent oxidation and maintain connection integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical connectors are used for signal-level connections, then the connection structure is simple, but the contact force is insufficient leading to oxidation and corrosion
Solution Approach 1:
The patent employs a dynamic spring mechanism that continuously applies contact force to the conductive pads. The spring's elastic properties enable it to maintain constant pressure despite thermal expansion, mechanical vibration, or assembly variations, ensuring reliable electrical contact and preventing oxidation at the interface.
Solution Approach 2:
The patent changes the mechanical parameter of contact force by introducing a spring element with specific elastic properties. The spring's force constant and pre-compression are optimized to provide sufficient contact pressure for signal-level connections, transforming a static rigid connection into a dynamic force-maintaining connection.
2Reliability
If higher contact force is applied to prevent oxidation, then the electrical connection reliability improves, but the risk of damaging conductive pads increases
Solution Approach 1:
The spring's elastic properties provide a self-regulating contact force that adapts to the mechanical properties of the conductive pads. The force-displacement characteristic of the spring ensures sufficient contact pressure for electrical reliability while the elastic compliance prevents excessive force that could damage the pads, achieving an optimal balance between connection integrity and component protection.
Solution Approach 2:
The spring element acts as a cushioning mechanism that absorbs mechanical shocks and thermal expansion forces before they can transmit damaging stress to the conductive pads. This preliminary cushioning protects the fragile signal-level contact interfaces while maintaining adequate contact force for 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 helical spring connector effectively maintains contact integrity by providing sufficient normal force at the points of contact, reducing oxidation and corrosion, and offering a cost-effective solution without the need for expensive dielectric materials or complex assembly processes.
Implementation Method 1
at least a portion of a helical spring is disposed within the plurality of holes and configured to contact one or more conductive pads on a surface of an other circuit board
Implementation Method 2
at least one of the plurality of holes is plated with an electrically conductive material
Data Source
AI summary
A low-cost electrical connector that is capable of providing a single or a multiplicity of continuous electrical connections between two individual printed circuit boards, and method of making thereof.