PCB Plug-In Connector Assembly With Nested Press-In Housing
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Solution Overview
Problem
The challenge lies in creating a modular plug-in connector device for vehicles that can seamlessly integrate various types of plug-in connector elements, including those connected via soldered and press-in contacts, while ensuring reliable and fluid-tight connections to accommodate different sizes and applications, particularly in demanding environments like the engine compartment.
Innovation Solution
A plug-in connector device comprising a printed circuit board with a first plug-in connector element connected via soldering and a second element connected via press-in contacts, where the second element's housing section has a recess to receive the first element, ensuring alignment and protection, and optionally featuring sealing elements for fluid-tight contact and a tapering shape for easy mounting, along with metallic signal shielding for high-speed data transmission elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different types of plug-in connector elements (soldered and press-in contacts) are integrated in a common device, then the adaptability and versatility of the connector device is improved, but the device complexity increases
Solution Approach 1:
The housing section is designed with a universal recess structure that can accommodate both soldered plug-in connector elements and press-in contact elements. The recess is configured to receive different types of connector elements through their respective connection methods, allowing a single housing to perform multiple connection functions without requiring separate housing designs for each connector type.
Solution Approach 2:
The plug-in connector element is nested within the recess of the housing section. The connector element is inserted into the recess such that its outer surfaces make contact with the inner surfaces of the recess, creating a nested configuration where the connector element is received and protected by the housing structure while maintaining electrical and mechanical connection to the printed circuit board.
2Shape
If the first plug-in connector element is received flush in the recess, then the alignment and compactness of the device is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The recess is designed with specific local geometric features including tapered walls and rounded corners that facilitate the flush reception of the plug-in connector element. The tapered configuration of the recess walls provides guiding surfaces that automatically align the connector element during insertion, while the rounded corners compensate for dimensional variations and ensure proper seating of the element in the recess.
3Reliability
If the outer surfaces of the first plug-in connector element make contact with the inner surfaces of the recess, then the protection and stability of the connector element is improved, but the ease of manufacture decreases
Solution Approach 1:
The recess is designed with tapered walls having a specific angle range (5-15 degrees) that changes the geometric parameters to facilitate automatic alignment and contact between the connector element outer surfaces and the recess inner surfaces. This tapered configuration transforms the assembly process, allowing the components to self-align during insertion while maintaining reliable contact and protection without requiring high-precision manual adjustment.
Data Source
AI summary
A plug-in connector device has a printed circuit board element, a first plug-in connector element which is electrically and mechanically connected to the printed circuit board element by a soldered connection, and a second plug-in connector element which is electrically and mechanically connected to the printed circuit board element by electrical press-in contacts. The second plug-in connector element has a housing section with a recess in which the first plug-in connector element is arranged in such a way that outer surfaces of the first plug-in connector element make contact with inner surfaces of the recess.