PCB Connector Stepped Contact Surface for Tolerance-Robust Reliability
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Solution Overview
Problem
Existing connectors for printed circuit boards face challenges in providing stable and efficient electrical connections due to variations in manufacturing tolerances and material properties, leading to inconsistent contact reliability.
Innovation Solution
A connector design featuring a leg portion and a cover portion with a stepped inner surface configuration, allowing for precise alignment and stable contact with the printed circuit board, enhancing electrical connectivity and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional connector design with a single flat surface is used, then the manufacturing process is simple, but the contact reliability is inconsistent due to manufacturing tolerances and material properties
Solution Approach 1:
The connector's contact surface is divided into multiple flat surfaces at different heights (first flat surface, second flat surface, third flat surface) instead of a single uniform surface. Each flat surface is positioned to contact the contact element at different locations, ensuring that at least one surface provides reliable electrical connection regardless of manufacturing tolerances or contact element variations.
2Reliability
If the connector structure is made more complex to improve contact reliability, then connection stability improves, but the manufacturing precision requirements increase
Solution Approach 1:
The contact surface is segmented into multiple flat surfaces (first, second, and third flat surfaces) at different heights along the extension direction of the contact element. This segmentation allows each surface to independently engage with the contact element at different positions, ensuring that manufacturing variations in one area do not affect overall connection stability.
Solution Approach 2:
The connector introduces height variation (z-dimension) with flat surfaces at different elevations rather than relying solely on lateral positioning. This dimensional approach allows the connector to accommodate manufacturing tolerances by providing multiple contact planes, reducing the stringency of precision requirements for each individual surface.
3Adaptability or versatility
If a stepped inner surface configuration is implemented, then accommodation of manufacturing variations is improved, but the device complexity increases
Solution Approach 1:
The inner surface of the connector is designed with localized variations in height, creating first, second, and third flat surfaces at different elevations. Each flat surface is strategically positioned to contact the contact element at different locations, allowing the connector to adapt to manufacturing variations in the contact element's position or dimensions.
Data Source
AI summary
An electronic device includes: a printed circuit board, a contact located around the printed circuit board, and a connector, disposed on the printed circuit board, and configured to electrically connect the contact and the printed circuit board. The connector includes a leg portion in contact with the printed circuit board and a cover portion extending from the leg portion and in contact with the contact. An inner surface of the cover portion facing a direction of the contact has a step shape including a first flat surface and a second flat surface parallel to the first flat surface and positioned at a different height from the first flat surface. The contact is in contact with the first flat surface from among the first flat surface and the second flat surface of the inner surface of the cover portion.