Resilient Micro Lattice Truss for PCB Interconnection
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Solution Overview
Problem
Conventional methods for establishing electrical connections between stacked printed circuit boards are time-consuming to assemble and difficult to reassemble for maintenance or repair, requiring careful realignment and often involving tedious manual processes.
Innovation Solution
A resilient, conductive micro lattice truss structure is formed using 3D printing and subsequently plated with conductive material, allowing for easy assembly and reassembly by compressing and decompressing to establish and break electrical connections between parallel surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional metal springs are used to establish electrical connections between PCBs, then electrical connection is achieved, but assembly becomes time-consuming and tedious
Solution Approach 1:
The patent changes the physical parameters of the spring element by optimizing its geometry (coil diameter, wire diameter, number of turns) and material properties to achieve the desired electrical and mechanical performance while simplifying assembly. This allows the spring to provide reliable electrical connection with reduced assembly complexity and time
Solution Approach 2:
The patent employs composite construction by combining the spring element with conductive materials and insulating materials in a single integrated component. This composite approach eliminates the need for separate assembly steps for electrical connection and mechanical support, thereby reducing assembly time while maintaining connection reliability
2Reliability
If conventional metal springs are used to establish electrical connections between PCBs, then electrical connection is achieved, but disassembly and reassembly become difficult
Solution Approach 1:
The patent incorporates a dynamic spring element that can compress and expand, allowing the connection to be easily made and broken. The spring's elastic properties enable it to accommodate repeated assembly and disassembly cycles without permanent deformation, making maintenance and repair significantly easier while maintaining electrical connection reliability
Solution Approach 2:
The spring's mechanical parameters (force constant, travel distance) are optimized to provide sufficient contact force for reliable electrical connection during normal operation, while allowing easy compression for disassembly. This parameter optimization enables simple push-to-connect and release operations for maintenance activities
3Reliability
If rigid perpendicular conductive pins are used to establish electrical connections, then connection is established, but alignment precision is required and reassembly is difficult
Solution Approach 1:
The patent replaces rigid pins with a flexible spring element that can accommodate misalignment and positional variations. The spring's elastic deformation capability allows it to compensate for manufacturing tolerances and assembly variations, eliminating the need for precise alignment while maintaining reliable electrical connection
Solution Approach 2:
The spring's geometric parameters are designed to provide adequate compliance in the direction of potential misalignment, allowing the connection to be established without precise alignment. The spring maintains sufficient electrical contact force despite positional variations, reducing manufacturing precision requirements
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 micro lattice truss structure significantly reduces assembly time and facilitates easy reassembly by maintaining structural integrity and conductivity, enabling efficient and reliable electrical connections with minimal ohmic resistance.
Implementation Method 1
The micro lattice truss structure is formed with resiliency so that the truss structure maintains structural integrity during moderate compression of its second end towards the first end. The resiliency of the micro lattice truss structure enables the truss structure to return to substantially its uncompressed length when the compression is removed.
Implementation Method 2
The micro lattice truss structure is conductive so that a resilient electrical connection can be formed between the conductive area of the first PCB and another spaced apart surface parallel with the first PCB when the second distal end of the truss structure is in contact with and compressed by the other surface.
Data Source
AI summary
An elongate, three dimensional, conductive, micro lattice truss structure has parallel layers of resilient strands so that the truss structure maintains structural integrity during end-to-end compression which shortens its uncompressed length. The resiliency of the micro lattice truss structure enables the truss structure to return to substantially its uncompressed length when the compression is removed. The truss structure is adapted to provide a resilient electrical connection between two opposing conductive areas on parallel spaced-apart printed circuit boards when the distal ends of the truss structure engage and are compressed between the two areas.