Mounting Plate Anchor Features Align Layered Electronic Assemblies
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Solution Overview
Problem
Layered electronic assemblies face significant tolerance stacking issues due to manufacturing inaccuracies, leading to misalignment of electrical contacts and requiring complex and costly flexible interconnects for compensation.
Innovation Solution
The use of compression connectors with perpendicularly extending pins and a mounting plate with anchor features allows for precise alignment and assembly of electronic components without soldering, reducing tolerance deviations and assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If specialized flexible interconnects are used to compensate for tolerance stacking issues, then alignment of electrical contacts between layers is improved, but device complexity and assembly time increase
Solution Approach 1:
The invention divides the assembly system into modular components: a mounting plate with anchor features, layer assemblies with alignment features, and standardized connectors. Each layer assembly is an independent module that can be manufactured separately and assembled systematically, reducing overall assembly complexity while maintaining precision
Solution Approach 2:
The invention replaces complex flexible interconnects and soldering processes with a mechanical alignment and attachment system. Alignment features (pins, holes, registration marks) provide precise positioning, while simple mechanical fasteners replace sophisticated interconnect structures, thereby reducing device complexity
2Manufacturing precision
If specialized flexible interconnects and soldering techniques are used, then electrical contact alignment is improved, but assembly time increases
Solution Approach 1:
Alignment features such as pins, holes, and registration marks are pre-formed during the manufacturing of individual layer assemblies. This preliminary preparation eliminates the need for time-consuming alignment operations during final assembly, as components are designed to self-align through their inherent geometric features
Solution Approach 2:
The invention replaces time-consuming soldering processes with rapid mechanical attachment methods. Standardized connectors and simple fasteners enable quick connection of layers without requiring skilled soldering operations, thereby significantly reducing assembly time while maintaining electrical contact precision
3Ease of manufacture
If conventional manufacturing methods are used for ceramic components, then manufacturing flexibility is maintained, but manufacturing precision of electrical contact locations deteriorates
Solution Approach 1:
The invention applies different quality requirements to different features of ceramic components. While electrical contact locations require high precision, other features (overall dimensions, non-critical surfaces) can be manufactured with standard tolerances. This selective approach maintains manufacturing flexibility for non-critical features while ensuring precision where needed through targeted processes
Solution Approach 2:
The mounting plate with anchor features serves as an intermediary reference frame that compensates for tolerances in individual ceramic components. By establishing a precise external reference system, the invention allows ceramic components to be manufactured with standard tolerances while achieving precise overall alignment through the intermediary mounting structure
4Adaptability or versatility
If independent electronic components are used in the first layer, then design flexibility is improved, but tolerance stacking issues worsen
Solution Approach 1:
The invention maintains segmentation of independent electronic components in the first layer for design flexibility, but introduces alignment features on each component that enable systematic assembly. The mounting plate with anchor features provides a reference framework that accommodates multiple independent components while controlling their relative positions, thereby managing tolerance stacking without sacrificing component independence
Solution Approach 2:
The mounting plate acts as an intermediary reference structure between independent electronic components and subsequent layers. It provides anchor features that establish precise reference locations, allowing independent components to be positioned with controlled tolerances. This intermediary framework enables design flexibility at the component level while ensuring overall assembly precision
Data Source
AI summary
Mechanisms for aligning electrical contacts of electronic components in a multiple layer electronic assembly are disclosed. A mounting plate is configured to align multiple layers of the multiple layer electronic assembly. The mounting plate includes a surface that a plurality of first anchor features at first predetermined locations of the surface configured to anchor a plurality of first layer electronic assemblies with respect to the surface. The mounting plate also includes a plurality of second anchor features at second predetermined locations configured to anchor at least one second layer electronic assembly with respect to the plurality of first layer electronic assemblies.