Non-Planar Connector Geometry for 3D Electronic Assembly Integration
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Solution Overview
Problem
Existing connector technologies are limited to planar connections, restricting design capabilities and complicating manufacturing processes for non-planar electronic assemblies and sub-assemblies, particularly in advanced microsystems and printed circuit board assemblies.
Innovation Solution
A non-planar connector system comprising male and female components with configurable interfaces, fabricated using additive manufacturing techniques, allowing for flexible and cable interconnects across non-planar geometries, and incorporating passive and active electronic devices for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional planar connectors and linear circuit networks are used, then manufacturing processes are simplified, but design capabilities are limited to planar or substantially planar assemblies
Solution Approach 1:
The patent applies curvature by transitioning from linear/orthogonal circuit paths to curved circuit networks that follow non-planar surfaces. The PSI structure enables circuits to bend and curve across three-dimensional surfaces, allowing connectors to be positioned on complex geometries while maintaining manufacturability through additive manufacturing processes.
Solution Approach 2:
The invention moves from two-dimensional planar connections to three-dimensional non-planar connections. By utilizing volumetric additive manufacturing, the system creates circuit networks that extend through multiple layers and dimensions, enabling connectors to be integrated on surfaces with complex spatial relationships.
2Ease of operation
If mounting members are added to provide connection points for traditional connectors on non-planar surfaces, then connectivity is achieved, but the surface of the electronic device is disrupted and manufacturing complexity increases
Solution Approach 1:
The patent merges the connector mounting function directly into the non-planar surface structure itself. Instead of adding separate mounting members that disrupt the surface, the PSI structure integrates connection points as part of the continuous curved circuit network, eliminating the need for additional components and preserving surface integrity.
Solution Approach 2:
The non-planar surface structure provides its own connection points through the PSI circuit network. The curved circuits inherently create suitable connection interfaces without requiring external mounting members, allowing the structure to serve its own connectivity needs.
Data Source
AI summary
A non-planar connector including a first non-planar connector component coupled to a first electronic assembly, the first non-planar connector component having at least one male circuit interface and a second non-planar connector component coupled to a second electronic assembly, the second non-planar connector component having at least one female circuit interface, each of the at least one female circuit interfaces corresponding to one of the at least one male circuit interfaces. When the first nonplanar connector component and the second non-planar connector components are in a mating arrangement, the at least one male circuit interface align and are coupled to the at least one female circuit interface and the first electronic assembly is integrated electrically with the second electronic assembly. A shape of the first non-planar connector component is configured to couple with a shape of the second non-planar connector component in the mating arrangement.