Low-Profile PCB Connector with Keyed Alignment and Rear Wire Routing
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Solution Overview
Problem
Existing connectors for printed circuit boards (PCBs) often obstruct light from LEDs, require soldering, and can lead to incorrect PCB placement, while also not allowing for easy replacement or continuous lighting without breaks between PCBs.
Innovation Solution
A connector system with a low-profile housing and keyed features that allows PCBs to mount directly on a surface, features elastic connecting terminals for secure engagement with contact pads, and includes wire insertion ports for routing wires behind the mounting surface, preventing obstruction and ensuring proper alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a connector is used to electrically connect PCBs, then electrical connectivity is achieved, but the connector obstructs light from LEDs
Solution Approach 1:
The connector housing is nested within a cavity in the mounting surface, positioning the connector body below the PCB level. This allows the electrical connection function to be achieved while the housing does not protrude to obstruct LED light, effectively nesting the connector within the mounting structure.
Solution Approach 2:
The connector terminals extend horizontally rather than vertically, changing the orientation of the electrical connection from a vertical protrusion to a horizontal engagement at the PCB underside, thereby eliminating light obstruction while maintaining connectivity.
2Illumination intensity
If PCBs are placed adjacent to one another for continuous lighting, then continuous illumination is achieved, but incorrect placement occurs without proper alignment features
Solution Approach 1:
Keyed features with asymmetric geometry are provided on both the connector housing and PCBs, preventing incorrect placement through geometric constraint. The keyed feature on the housing engages with the corresponding keyed feature on the PCB edge, ensuring precise alignment and orientation.
3Reliability
If traditional connector mounting is used, then electrical connection is achieved, but PCB replacement is difficult
Solution Approach 1:
The connector is designed as a separate, replaceable component mounted in a cavity, with PCBs that can be independently removed and replaced. The modular design allows PCBs to be exchanged without replacing the entire assembly, facilitating easy repair and maintenance.
4Reliability
If wires are routed in front of the mounting surface, then electrical connection is achieved, but wires obstruct light from LEDs
Solution Approach 1:
Wire routing is moved from the front horizontal plane to the rear vertical plane of the mounting surface. Wires are routed from behind the mounting surface through the cavity, changing the routing dimension from front-to-back to behind-the-surface, thereby eliminating light obstruction while maintaining electrical connectivity.
Data Source
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AI summary
A connector for electrically connecting a first printed circuit board (PCB) with a second PCB wherein, in one example, the connector includes a housing having a keyed feature adapted to mate with a correspondingly keyed feature provided to each of the first and second PCBs and at least one connecting terminal carried by the housing having at least partially exposed opposed ends each of which electrically engages a contact pad formed on an underside of the respective PCBs. The connecting terminal may be arranged to accept a conductor and to thereby electrically couple the conductor to the first and second PCBs.