Modular PCB Connector Layout for High-Current Board Mating
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Solution Overview
Problem
Conventional board-to-board connectors have fixed terminal positions, limiting flexibility, are susceptible to mechanical stress, and suffer from slow installation, which complicates design, increases costs, and fails to meet high-current requirements in automotive applications.
Innovation Solution
A modular connector comprising a signal module and power module with engaging parts that can be connected and disconnected, allowing for customizable module combinations and rapid assembly, reducing high-temperature generation through dispersed current paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed terminal positions are used in conventional board-to-board connectors, then manufacturing and design are simplified, but flexibility and adaptability to different circuit board layouts are limited
Solution Approach 1:
The connector is divided into multiple independent modules, each containing a specific number of terminals. These modules can be selectively combined to create connectors with different terminal configurations, enabling adaptability to various circuit board layouts without increasing overall structural complexity
Solution Approach 2:
The connector design allows dynamic reconfiguration of terminal positions by selecting different module combinations. The engaging parts enable modules to be connected in various sequences and orientations, providing flexibility while maintaining a standardized modular structure
2Reliability
If fixed connector designs are used, then manufacturing is simplified, but susceptibility to mechanical stress increases during frequent connection and disconnection
Solution Approach 1:
By segmenting the connector into modular units with standardized engaging parts, each module can independently absorb mechanical stress during connection and disconnection operations, reducing the cumulative stress on the entire connector assembly and improving durability
Solution Approach 2:
The modular design with engaging parts incorporates stress-distribution features that preemptively cushion mechanical loads before they propagate through the entire connector structure, protecting against damage during frequent mating operations
3Productivity
If conventional fixed designs are used, then structural simplicity is maintained, but installation speed is slow, limiting production efficiency
Solution Approach 1:
The connector is segmented into pre-assembled modules that can be quickly attached to circuit boards in predetermined configurations. This modular approach enables parallel assembly operations and reduces installation time compared to conventional fixed designs, despite the increased structural complexity of multiple modules
Solution Approach 2:
Modules are pre-assembled with their internal terminals and engaging parts before being delivered for final installation. This preliminary preparation allows for rapid deployment during production, improving installation speed while the modular complexity is managed through standardized designs
4Power
If conventional connector designs are used, then design simplicity is maintained, but ability to meet high-current requirements is limited
Solution Approach 1:
High-current power transmission is achieved by segmenting the power delivery across multiple parallel terminal modules. This distributes the current load across several contact paths, enabling high-current capability while managing thermal and structural complexity through the modular architecture
Data Source
AI summary
The modular connector is disposed on a printed circuit board for insertion by a mating connector. The modular connector includes at least one signal module, a plurality of power modules, and a cover. Each signal module includes a first insulating housing and a plurality of first contact elements. Each power module includes a second insulating housing and a plurality of second contact elements. The at least one signal module is detachably connected between the power modules, and the mating connector has a plurality of signal contact elements and a plurality of power contact elements. When electrically connected, the signal contact elements and the power contact elements respectively correspond to and make contact with the first contact elements and the second contact elements. The modular connector is able to simultaneous transmit signals and currents, and the signal modules and the power modules offer combinational selectivity.