Panel Mount Connector With Flexible Circuit Board
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Solution Overview
Problem
Traditional panel mount connectors face issues with mechanical stress and damage during installation and use due to rotational movement, which can harm pins and solder joints, and existing solutions are either skill-dependent or require complex installation procedures.
Innovation Solution
A panel mount connector design featuring a flexible circuit board and a retainer ring that allows independent movement of the external connection interface relative to the connector shell, reducing mechanical stress and enabling secure installation without damaging the pins or solder joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the connector shell is rigidly fixed to the panel, then the installation stability is improved, but the pins and solder joints are subjected to significant mechanical force causing damage
Solution Approach 1:
The connector is divided into separate functional components: a rigid connector shell for stable panel mounting, and a flexible circuit board assembly containing the pins. This segmentation allows the shell to provide installation stability while the flexible pins isolate the solder joints from mechanical stress during torqueing operations.
Solution Approach 2:
The flexible circuit board acts as an intermediary element between the rigid connector shell and the rigid printed circuit board. It absorbs and isolates the mechanical forces generated during installation, preventing these forces from being transmitted to the solder joints while still maintaining electrical connectivity.
2Object-affected harmful factors
If the connector allows rotational movement during installation, then the mechanical stress on pins is reduced, but the installation precision and alignment are compromised
Solution Approach 1:
The flexible circuit board's mechanical properties are optimized to allow controlled deformation within specific parameters. It can accommodate limited rotational movement and misalignment during installation while maintaining sufficient precision for proper connector engagement, effectively changing the rigidity parameter from rigid to flexibly rigid.
3Device complexity
If a traditional rigid connector design is used, then the structural simplicity is maintained, but the reliability of pins and solder joints deteriorates under operational forces
Solution Approach 1:
The circuit board is constructed with flexible materials and a thin-film structure that enables it to bend and deform elastically. This flexible construction allows the pins to move independently of the connector shell, absorbing operational forces such as over-tightening of mating connectors while maintaining reliable electrical connections.
4Stability of the object's composition
If the pins are independently fixed to the printed circuit board, then the electrical connection stability is improved, but the connector shell movement causes damage to the solder joints
Solution Approach 1:
The system transitions from a static rigid connection to a dynamic flexible connection. The flexible circuit board can deform and move relative to both the connector shell and the printed circuit board, allowing the pins to maintain stable electrical connections while the board itself absorbs and isolates forces that would otherwise damage the solder joints.
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 solution effectively reduces the risk of damage to pins and solder joints by allowing significant relative movement, accommodating rotational and linear displacements, thereby enhancing the reliability and durability of the connector during installation and field use.
Implementation Method 1
a flexible circuit board supported substantially within the through passage... allowing significant relative movement
Data Source
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AI summary
A panel mount connector and method involve a connector shell assembly that is configured to be received in an opening that is defined by a panel with the connector shell defining a through passage. A flexible circuit board is supported within the through passage and defines a first external connection interface at one end for external electrical access from one side of the panel when the connector shell assembly is installed in the panel and at least the first external connection interface is supported for independent movement relative to the connector shell.