Open-Slit PCB Tail Contact for Low-Force Durable Mating
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Solution Overview
Problem
Existing connector systems face challenges in achieving low insertion force while maintaining high mating durability and electrical contact reliability, especially in environments with varying temperature, vibration, and impact conditions.
Innovation Solution
A low-force, high mating durability, open-ended compliant printed circuit (PC) tail contact system with a compliant portion featuring two or more deflectors with an open slit, designed to provide a spring-like action, allowing for easy insertion and extraction, and maintaining electrical contact through a range of conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional rigid PC tail contact is used, then manufacturing precision is improved, but insertion force increases and mating durability decreases
Solution Approach 1:
The PC tail contact is segmented into multiple functional portions: a rigid contact portion for precise electrical connection, a compliant portion with deflectors for flexible insertion, and a shoulder portion for positioning. This segmentation allows each portion to perform its specific function optimally without compromising overall performance
Solution Approach 2:
Different portions of the PC tail contact have different mechanical properties: the contact portion maintains rigidity for precise alignment and electrical connection, while the compliant portion with deflectors provides flexibility and spring-like action for low insertion force. This local differentiation of mechanical properties resolves the contradiction between precision and ease of insertion
2Device complexity
If a traditional rigid PC tail contact is used, then structural simplicity is improved, but mating durability under vibration and impact decreases
Solution Approach 1:
The PC tail contact transitions from a static rigid structure to a dynamic structure with compliant portions that can deflect and absorb mechanical shocks from vibration and impact. The spring-like action of the deflectors allows the contact to dynamically adapt to environmental stresses while maintaining reliable electrical connection
Solution Approach 2:
The compliant portion with deflectors acts as a pre-designed shock absorption mechanism that cushions against vibration and impact forces before they can damage the electrical connection. This beforehand cushioning protects the mating interface under harsh environmental conditions
3Quantity of substance
If the compliant portion includes more deflectors, then current carrying capacity increases, but device complexity increases
Solution Approach 1:
The current carrying capacity is adjusted by changing the number of deflectors in the compliant portion (two, three, or four deflectors). This parameter change allows optimization of electrical performance while the deflectors are integrated into the existing compliant portion structure, minimizing the increase in overall device complexity
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 system achieves low insertion force, increased contact surface, and enhanced durability, ensuring reliable electrical contact even under varying environmental conditions, with improved current carrying capacity and reduced contact resistance.
Implementation Method 1
a compliant pin coupled to the tail portion, the compliant pin comprising two or more deflectors with an open slit
Data Source
AI summary
A printed circuit (PC) tail contact includes a low-force, high mating durability, open-ended, compliant portion. The PC tail contact is structured with a contact portion to mate with a corresponding contact of another connector, a shoulder portion coupled to the contact portion to position the PC tail contact within the insulator of the PCB connector, a tail portion coupled to the shoulder portion, and the compliant portion coupled to the tail portion. The compliant portion may include two, three, or four deflectors with an open slit based on one or more of an internal diameter of a PCB through-hole or a current to be carried by the PC tail contact.