Inline Circuit Board Connector System with Elongated Prongs
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Solution Overview
Problem
Conventional circuit board mating systems require different connectors for each board, leading to complex installation and maintenance, and are often hindered by conformal coatings that obstruct electrical connections.
Innovation Solution
An inline connector system with identical female connectors on each substrate and a header connector with elongated prongs that can break through conformal coatings to establish electrical connections between boards, allowing for uniform design, easy installation, and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional male-female connectors are used on circuit boards, then electrical connections can be established, but the installation complexity increases and maintenance becomes difficult due to polarity requirements and different connector types
Solution Approach 1:
The patent applies asymmetry by using identical female connectors on both circuit boards while the header connector has a specific orientation with prongs that must be inserted in a particular direction. This asymmetric design eliminates the need for matching male-female connectors and simplifies installation by allowing any board to connect to any other board without polarity concerns.
Solution Approach 2:
The patent implements universality by using the same female connector type on all circuit boards. This universal connector design allows any circuit board to interface with any other board or with the power supply unit, eliminating the need for different connector types and simplifying both installation and maintenance operations.
2Reliability
If conformal coating is applied to circuit boards for protection, then reliability against environmental factors improves, but electrical connections are obstructed by the coating material
Solution Approach 1:
The patent applies preliminary action by designing the header connector prongs to be sufficiently long and rigid to penetrate through the conformal coating on the circuit board surface. This preliminary design consideration ensures that the electrical connection can be established through the protective coating without requiring removal or modification of the coating itself.
Solution Approach 2:
The header connector acts as an intermediary element that bridges the gap between the uncoated connector contacts and the coated circuit board contacts. The elongated prongs serve as a mediator that reaches through the conformal coating to establish electrical contact with the underlying contacts.
3Ease of repair
If modular circuit board design is used for easy maintenance, then individual board replacement is simplified, but connection alignment and securing become more challenging
Solution Approach 1:
The patent applies segmentation by designing the connector system as separate, modular components: female connectors mounted on individual circuit boards and a separate header connector with prongs. This segmentation allows individual circuit boards to be easily removed and replaced by simply disconnecting and reconnecting the header, simplifying maintenance operations.
Solution Approach 2:
The patent combines multiple functions into the header connector: it provides electrical connections through its prongs, mechanical alignment through its structure, and secure attachment through the receptacle engagement. This merging of functions into a single component simplifies the overall connection mechanism while maintaining ease of board replacement.
Data Source
AI summary
An inline connector is coupled to a first substrate and operable to receive at least one prong. A second receptacle is coupled to a second substrate and operable to receive the prong. A plug having an elongated prong that, when inserted through the first receptacle and into the second receptacle operates to provide electrical connections between the substrates. The substrates may be circuit boards and the receptacle may be mounted along the edges of the circuit board to allow for easier installation. Some embodiments may provide for identical receptacle providing for lower costs and easier installation.