PCB Cable Connector Structure for Compact Direct Soldering
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Solution Overview
Problem
Existing connector technologies for connecting printed circuit boards to conductors are often bulky, require multiple components, and occupy significant installation space, making them inefficient and difficult to automate.
Innovation Solution
A connector design featuring one or more fasteners, a recess, and two openings: the first opening for conductor insertion and the second opening for heat application to establish a direct solder connection, minimizing components and space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connector technologies are used to connect printed circuit boards to conductors, then reliable electrical connection is achieved, but the connector becomes bulky and occupies significant installation space
Solution Approach 1:
The patent combines multiple functions into a single integrated connector component. The connector integrates the housing, fastening mechanism, and conductor insertion features into one compact unit, eliminating the need for separate mounting brackets, fasteners, and alignment features that would otherwise be required. This merging of functions directly reduces the overall installation space while maintaining connection reliability.
Solution Approach 2:
The connector utilizes the z-dimension (vertical thickness) efficiently by designing a low-profile structure that extends minimally from the printed circuit board surface. The conductor insertion path is optimized to accommodate conductor diameters up to 3mm while maintaining a compact overall height, effectively using vertical space to reduce the horizontal footprint and installation area.
2Strength
If traditional connector designs with multiple components are used, then adequate mechanical support and electrical connection are provided, but the assembly process becomes complex and difficult to automate
Solution Approach 1:
The connector integrates the mechanical fastening function and electrical connection function into a single component. The housing incorporates built-in fastening features that directly secure the connector to the printed circuit board while simultaneously providing the electrical connection pathway, eliminating the need for separate mechanical fasteners and electrical contacts that would complicate assembly.
Solution Approach 2:
The connector features self-aligning and self-securing mechanisms that automatically position and secure the conductor during insertion. The housing includes integrated guide features and retention elements that automatically engage with the conductor and PCB, eliminating the need for complex alignment procedures or multiple assembly steps, thereby enabling automated assembly.
3Reliability
If conventional connector technologies are used, then electrical connection is established, but the connector requires multiple components increasing device complexity
Solution Approach 1:
The patent merges the housing, fastening mechanism, conductor guide, and electrical connection features into a single integrated connector component. This consolidation reduces the bill of materials and assembly complexity while maintaining all necessary functions for reliable electrical connection between the printed circuit board and conductor.
Solution Approach 2:
The connector is designed as a multi-functional component that simultaneously provides mechanical mounting, electrical connection, conductor guidance, and signal shielding. This universal design approach allows a single component to replace what would traditionally require multiple specialized parts, reducing overall device complexity while ensuring reliable electrical connection.
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 enables a compact, efficient, and automated connection process between printed circuit boards and conductors, reducing installation space requirements and simplifying assembly steps.
Implementation Method 1
Heat for connecting the at least one conductor to the at least one solder pad is providable through the second opening
Data Source
AI summary
A connector for connecting a printed circuit board, which comprises a solder pad, to a conductor of a line includes one or more fasteners, a recess and a second opening. The connector is fastenable to the printed circuit board by the one or more fasteners. The recess is formed on a first side of the connector and extends at least over a second side arranged transversely to the first side. In an assembled state of the connector on the printed circuit board, the solder pad is arrangeable in the recess on the first side, and, on the second side, the recess forms a first opening into which the conductor is insertable. The second opening is formed on a third side opposite the first side. Heat for connecting the at least one conductor to the solder pad is providable through the second opening.