PCB Interconnect via Asymmetric Clamping Force
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Solution Overview
Problem
Existing methods for connecting printed circuit boards are often complex, require SMT technology, or need multiple connection elements, making them difficult to implement efficiently and reliably.
Innovation Solution
A one-piece connection element with contact elements at both ends, housed in an insulating body, which can be plugged into plated-through holes for secure clamping, allowing for easy handling and adjustable clamping force to ensure correct alignment and detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional plug connections with two separate housing parts are used, then electrical connection between printed circuit boards is achieved, but device complexity increases and manufacturing becomes more difficult
Solution Approach 1:
The patent merges two separate housing parts into a single integrated housing structure. The one-piece connection element is housed in a single insulating body that contains both connection interfaces, eliminating the need for two separate housings and reducing assembly complexity while maintaining reliable electrical connection between printed circuit boards.
Solution Approach 2:
The single insulating body serves multiple functions simultaneously: it houses the connection element, provides mechanical support, ensures proper alignment, and enables handling of the entire connector assembly. This multi-functional design reduces the number of separate components needed while achieving the same connection reliability.
2Reliability
If multiple connection elements are used to establish conductive connection, then electrical connectivity is ensured, but ease of manufacture decreases and assembly becomes more difficult
Solution Approach 1:
Multiple connection elements are integrated into a single insulating body as one unified assembly. This allows the entire multi-element connector to be manufactured and handled as a single unit, significantly improving ease of manufacture and assembly compared to installing multiple separate connection elements individually.
Solution Approach 2:
The connection elements are pre-assembled and secured within the insulating body during manufacturing. This preliminary assembly ensures proper positioning and spacing of multiple contact elements before the connector is installed, simplifying the final installation process and reducing assembly complexity.
3Ease of operation
If connection elements are inserted without proper positioning, then insertion is simple, but manufacturing precision decreases due to misalignment
Solution Approach 1:
The insulating body acts as an intermediary structure that pre-positions and aligns the connection elements before insertion into the printed circuit board. It includes features such as guide ribs, positioning pins, or molded cavities that ensure the connection elements are correctly aligned with the target holes, maintaining manufacturing precision while keeping insertion simple.
Solution Approach 2:
The insulating body is pre-formed with the connection elements in their correct positions during manufacturing. This preliminary positioning ensures that when the connector is inserted, the contact elements are already aligned with the target holes, eliminating the need for complex alignment procedures during installation.
4Strength
If SMT technology is used to connect connection elements, then secure attachment is achieved, but ease of manufacture decreases due to specialized process requirements
Solution Approach 1:
The patent replaces the SMT (Surface Mount Technology) process with a mechanical insertion system. The connection elements are designed to be inserted directly into pre-drilled holes in the printed circuit board and secured through mechanical means such as friction fit, interference fit, or simple snap-in mechanisms, eliminating the need for specialized SMT equipment and processes while maintaining secure attachment.
Solution Approach 2:
The connection elements are designed as simple, inexpensive components that can be manually or automatically inserted without requiring expensive SMT equipment. The insulating body with integrated connection elements can be manufactured cost-effectively and replaced if needed, reducing manufacturing complexity and equipment requirements.
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
This solution simplifies the connection process, reduces the need for multiple elements, and ensures secure, adjustable connections between printed circuit boards, preventing misalignment and tilting issues, while allowing for detachable or permanent connections as needed.
Implementation Method 1
In this plated-through hole, the connecting element is fixed by clamping
Data Source
Figure 1~2
Figure 3~5
AI summary
In order to mechanically and electrically connect two printed circuit boards (26, 27) in a parallel arrangement, a plurality of connecting elements (1) is arranged in an insulating member (22) having parallel faces, said connecting elements projecting from both opposite faces of the insulating member. The projecting part of the connecting elements is designed as a contact element (6), thus allowing said contact elements to be plugged into plated-through bores (28) of the printed circuit boards. The contact elements are secured within the plated-through bores by means of a clamping force acting transverse to the plugging direction. The clamping force causes the contact elements to be pressed against the walls of the plated-through bores and thus both mechanically secures the contact elements and establishes an electric connection. According to the invention, the clamping force of the connecting elements is greater for one printed circuit board than the clamping force of the connecting elements for the other printed circuit board so as to ensure that the insulating member remains plugged in one of the printed circuit boards along with the connecting elements contained in the insulating member when the connection is released.