Housingless Connector Beam Projections Alignment
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Solution Overview
Problem
Existing housingless connectors face challenges in ensuring proper positioning and contact between conductive patterns, leading to unreliable electrical connections.
Innovation Solution
The design incorporates beam and surface projections formed between conductive patterns on mating connectors, with tapered tips and insulating materials, to ensure precise alignment and contact between conductive patterns, utilizing cantilevered beam parts and surface projections to facilitate reliable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional housingless connector design is used, then manufacturing simplicity is maintained, but positioning precision and contact reliability between conductive patterns deteriorate
Solution Approach 1:
The connector is divided into distinct functional components: beam parts with conductive patterns for electrical connection, and projection parts (with beam projections and surface projections) for positioning. This segmentation allows each component to be optimized independently - the beam parts maintain manufacturing simplicity while the projection parts provide precise positioning features that engage with corresponding recesses in the mating connector.
Solution Approach 2:
The projection parts act as intermediaries between the conductive patterns and the mating connector. These projections (beam projections inserted between beam parts, surface projections inserted between conductive patterns) serve as positioning mediators that ensure accurate alignment before electrical contact is made, resolving the contradiction by introducing a dedicated positioning mechanism without requiring complete redesign of the connector structure.
2Reliability
If conductive patterns are directly contacted without positioning features, then device complexity is reduced, but contact reliability deteriorates
Solution Approach 1:
The projection parts perform preliminary positioning action before the conductive patterns make contact. The beam projections are inserted between the beam parts and surface projections are inserted between the conductive patterns of the mating connector, establishing precise alignment in advance. This preliminary positioning ensures that when the conductive patterns eventually contact, they do so with high reliability, justifying the added structural complexity.
Solution Approach 2:
The invention replaces direct mechanical contact between conductive patterns with an indirect positioning system using projections and recesses. Instead of relying solely on the conductive patterns to find their mating partners through direct contact, the mechanical projection-recess system guides and positions them accurately, improving contact reliability while maintaining reasonable structural complexity.
Data Source
AI summary
A board-to-board connector includes a receptacle connector and a plug connector. The receptacle connector includes a plurality of beam parts having a metal plate and an insulating layer formed on the metal plate and a plurality of conductive patterns formed on the insulating layer of the plurality of beam parts. The plug connector includes a beam contact part having a metal plate and an insulating layer formed on the metal plate and a plurality of conductive patterns formed on the insulating layer of the beam contact part. A beam projection is formed between the adjacent conductive patterns of the plug connector, and the beam projection is inserted between the adjacent beam parts of the receptacle connector when the receptacle connector and the plug connector are mated.