PCB Connector Assembly With Self-Aligning Stacked Board Contacts
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Solution Overview
Problem
There is a need for a connector device that can be manufactured simply and connected reliably, while offering flexibility in implementing a wide range of electric functions.
Innovation Solution
A connector device comprising two printed circuit board elements with an electrically insulating core and conductive structures, where the elements are stacked and connected directly, with a plug recess formed between them for mechanical and electric connection, allowing for automatic alignment of conductive structures upon mechanical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional metal inserts surrounded by polymer are used for connector manufacturing, then complex mechanical shapes can be created with various physical properties, but the manufacturing process becomes complicated and time-consuming
Solution Approach 1:
The patent changes the fundamental material parameter from traditional metal-polymer composite to PCB-based construction with copper traces on fiberglass substrate. This parameter change enables the connector to be manufactured using standard PCB fabrication processes, dramatically simplifying manufacturing while maintaining structural integrity and electrical functionality
Solution Approach 2:
The PCB-based connector structure serves multiple functions simultaneously: it provides mechanical support through the fiberglass substrate, electrical connection through copper traces and contact pads, and structural complexity through multi-layer construction. This multi-functionality eliminates the need for separate components that would otherwise be required in traditional connector designs
2Adaptability or versatility
If PCB-based construction with stacked elements is used, then manufacturing simplicity and flexibility are improved, but ensuring reliable mechanical and electrical alignment becomes challenging
Solution Approach 1:
The PCB elements are pre-manufactured with precisely positioned copper traces, contact pads, and mounting holes using standard PCB fabrication processes. This preliminary action ensures that when the PCB elements are stacked and connected, the electrical and mechanical alignment is already predetermined and guaranteed by the manufacturing precision of the PCB industry
Solution Approach 2:
The patent introduces intermediate connection elements such as conductive adhesives or spring contacts that facilitate reliable electrical connection between stacked PCB elements. These intermediaries compensate for minor dimensional variations and ensure consistent electrical contact, thereby solving the alignment precision challenge while maintaining manufacturing simplicity
Data Source
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AI summary
A connector device (600) for connection with a counter piece (1500) for establishing a mechanical and electric connection, wherein the connector device (600) comprises at least two printed circuit board elements (100) each comprising an electrically insulating core (102) and at least one comprising an electrically conductive structure (104) at least partially on the respective electrically insulating core (102), wherein the at least one electrically conductive structure (104) is arranged at least partially on an exposed surface of the connector device (600) and is configured for establishing the electric connection with the counter piece (1500) upon establishing the mechanical connection with the counter piece (1500).