Overmolded PCB Connector System for Mobile Devices
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Solution Overview
Problem
Printed circuit boards in mobile devices are prone to malfunction when exposed to contaminants like water or dirt, as existing connectors and housings require complex and imperfect sealing methods.
Innovation Solution
A molded connector system where a printed circuit board is encased in a resilient material, with connectors exposed for coupling to electronic components while being protected from contaminants, using overmolding or insert molding processes to simplify sealing and enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If printed circuit boards are exposed to contaminants like water or dirt, then they can be easily accessed and connected, but they malfunction due to contaminant exposure
Solution Approach 1:
The housing is divided into a first portion and a second portion that can be separated. The PCB is accessible when portions are separated for connection purposes, but protected when portions are assembled together, resolving the contradiction between accessibility and protection
Solution Approach 2:
The molded housing acts as an intermediary structure that provides controlled access to the PCB. Connectors are exposed through the housing structure, allowing connection while the housing material blocks contaminants from reaching the PCB
2Ease of operation
If connectors are exposed for easy connection, then coupling is facilitated, but contaminants can reach the PCB through the same exposure points
Solution Approach 1:
The housing structure provides different properties in different locations: areas with connectors have open access for coupling, while areas with the PCB provide contaminant protection. This local differentiation resolves the contradiction between exposure for connection and protection from contaminants
3Reliability
If complex sealing methods are used to protect PCB from contaminants, then reliability improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The protective housing and connector support structure are merged into a single molded component. The housing simultaneously provides contaminant protection and connector exposure functionality, eliminating the need for separate sealing mechanisms and reducing overall device complexity
Solution Approach 2:
The molded housing performs multiple functions: it protects the PCB from contaminants, supports and positions connectors, and provides structural integrity. This multi-functionality reduces the number of separate components needed and simplifies the overall device design
Data Source
AI summary
Described herein is a molded printed circuit board. The printed circuit board may be placed inside of a mold and a material is injected therein. The material hardens in the mold around the printed circuit board thereby forming an overmolded printed circuit board. The overmolded material may have apertures in it to allow access to the leads on the printed circuit board so that components to be connected to it. The overmolded printed circuit boards may allow a plurality of electrical components to selectively and removably attach to it. Further, the printed circuit board may be attached in a housing which may itself removably and selectively connect to components.