Hermaphroditic PCB Plug Connector for Vibration-Stable Contact Force Balance
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Solution Overview
Problem
Hermaphroditic circuit board plug connectors face challenges in manufacturing effort and cost due to complex designs, and they often compromise shock and vibration stability, as well as distributing contact pressure forces to sensitive circuit board connections.
Innovation Solution
A circuit board plug connector design featuring plug contacts of two types with distinct plug regions, allowing for secure plugging and compensation of contact pressure forces, reducing the load on circuit board connections, and utilizing stamped-and-bent parts for high conductivity and mechanical tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hermaphroditic plug connectors are designed with identical plug contacts that make contact on one side only, then manufacturing effort is reduced and production quantities can be doubled, but contact pressure forces are transmitted to sensitive circuit board connections and shock and vibration stability is reduced
Solution Approach 1:
The plug contacts are divided into two distinct types (first type and second type) with different plug region shapes. This segmentation allows each contact type to be optimized for specific functions: one type provides stable mechanical engagement while the other distributes contact pressure, thereby resolving the contradiction between manufacturing simplicity and connection reliability.
Solution Approach 2:
Different regions of the plug connector are assigned different contact characteristics. The first type of plug contact has a plug region shaped to provide frictional engagement and shock stability, while the second type has a plug region shaped to distribute contact pressure forces. This local differentiation maintains manufacturing efficiency while improving overall reliability.
2Reliability
If complex spring systems with several springs/contact springs are used in each plug contact element, then shock and vibration stability is improved, but design complexity and manufacturing costs increase significantly
Solution Approach 1:
The complex spring system is extracted from each individual plug contact element and replaced with a simpler design. Instead of multiple springs per contact, the invention uses two types of contacts with geometrically shaped plug regions that achieve stability through form rather than complex mechanical systems, thereby reducing design complexity while maintaining reliability.
Solution Approach 2:
The invention replaces expensive, complex spring systems with simpler, more cost-effective plug contact designs. The stamped-and-bent construction with geometrically optimized plug regions provides adequate shock and vibration stability without the high manufacturing costs associated with multiple springs per contact element.
3Manufacturing precision
If plug contacts are designed with stamped-and-bent construction, then electrical conductivity and mechanical tolerance are improved, but contact pressure force distribution to circuit board connections remains a challenge
Solution Approach 1:
The plug contacts are segmented into two types with different functional characteristics. The first type of plug contact is designed to absorb and distribute contact pressure forces through its specific plug region shape, while the second type provides stable mechanical engagement. This segmentation allows the stamped-and-bent construction to achieve both mechanical precision and favorable force distribution.
Solution Approach 2:
Different plug region shapes are assigned to different contact types based on their local functional requirements. The first type has a plug region optimized for force distribution to protect circuit board connections, while the second type has a plug region optimized for mechanical stability. This local quality differentiation resolves the contradiction between manufacturing precision and force distribution.
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 design enhances shock and vibration stability, reduces manufacturing complexity and costs, and ensures even distribution of contact pressure forces, maintaining high electrical conductivity and mechanical reliability.
Implementation Method 1
plug contacts of the first type and second type held by means of the contact carrier... compensation of contact pressure forces
Data Source
AI summary
In order to produce a circuit board plug connector in which the advantages of hermaphroditic plug connectors are combined with the advantages of conventional plug connectors, a contact carrier is equipped with both plug contacts of a first type and plug contacts of a second type in equal numbers. Advantageously, the plug contacts of the first type are designed as “male” contacts (blade contacts) and the plug contacts of the second type are designed as “female” contacts (fork contacts) and can be plugged into one another in principle.