Intermediate Connector Assembly for High-Tolerance Electrical Isolation
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Solution Overview
Problem
Existing methods for connecting electronic device components often require high manufacturing tolerances for individual elements, which can be costly and complex, and may not adequately address electrical isolation or interference issues between conductive elements.
Innovation Solution
Using an intermediate element that changes states to connect two or more elements, allowing for low-tolerance manufacturing of individual components while ensuring high-tolerance assembly and electrical insulation or isolation, achieved through materials like insulating or dielectric substances that form a structural bond between elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connection methods (snaps, mechanical fasteners, adhesives) are used to connect housing components, then the components can be securely connected, but high manufacturing tolerances are required for individual elements which increases manufacturing complexity and cost
Solution Approach 1:
A compliant connector is introduced as an intermediary element between two housing components. The connector includes a first portion that interfaces with a first housing component and a second portion that interfaces with a second housing component. The compliant nature of the connector allows it to deform and accommodate misalignments, thereby enabling secure connection while tolerating variations in manufacturing tolerances of the housing components.
Solution Approach 2:
The connector material is selected to have specific mechanical properties (compliance, elasticity) that allow it to change its physical state or deformation characteristics under load. This parameter change enables the connector to adapt to dimensional variations in the connected components, resolving the contradiction between connection reliability and manufacturing precision requirements.
2Strength
If conductive elements are used for structural components, then structural strength is achieved, but electrical interference or short circuits can occur between adjacent conductive components
Solution Approach 1:
The housing structure is divided into different regions with different material properties. Conductive materials are used in regions requiring electrical connectivity (such as antenna elements), while non-conductive materials are used in regions where electrical isolation is needed. The compliant connector itself can be designed with localized conductivity - conductive portions where structural strength is needed and non-conductive portions where electrical isolation is required.
Solution Approach 2:
The connector can be constructed from composite materials that combine conductive and non-conductive properties in a single component. This allows the connector to provide both structural strength and selective electrical isolation, enabling conductive elements to be connected structurally while preventing unwanted electrical interference between them.
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
This approach enables precise alignment and secure bonding of components with reduced manufacturing complexity, while maintaining electrical isolation and ensuring proper functionality of conductive elements, such as antennas, by using materials that flow and adhere to form a structurally sound connection.
Implementation Method 1
using an intermediate element that changes states to connect two or more elements
Implementation Method 2
the material of the intermediate element can include an insulating or a dielectric material
Implementation Method 3
the material of the intermediate element can include an insulating or a dielectric material
Data Source
AI summary
This is directed to connecting two or more elements using an intermediate element constructed from a material that changes between states. An electronic device can include one or more components constructed by connecting several elements. To provide a connection having a reduced or small size or cross-section and construct a component having high tolerances, a material can be provided in a first state in which it flows between the elements before changing to a second state in which it adheres to the elements and provides a structurally sound connection. For example, a plastic can be molded between the elements. As another example, a composite material can be brazed between the elements. In some cases, internal surfaces of the elements can include one or more features for enhancing a bond between the elements and the material providing the interface between the elements.