High-Density PCB Connector Retention for Vibration Endurance
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Solution Overview
Problem
There is a need for electrical connectors with high signal density and improved vibration endurance, particularly in automotive applications where connectors must remain mated despite environmental vibrations.
Innovation Solution
The design incorporates a terminal with a crimping end and a mating end, featuring an intermediate locking feature and a terminal position assurance (TPA) feature that engages with a housing to secure the terminal in place, ensuring reliable connection and resistance to vibration. Additionally, the connector configuration allows for reduced board pitch and accommodates large conductors, with features like latches and hold-downs to secure the connector to a printed circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connector design uses traditional terminal retention methods, then the structure is simpler, but the vibration endurance is insufficient and terminals may become dislodged
Solution Approach 1:
The terminal's locking feature is biased outwardly by a spring element and automatically engages with the housing feature during insertion. The biasing element provides continuous force to maintain engagement without requiring external actuation or complex retention mechanisms.
Solution Approach 2:
The locking feature acts as an intermediary element between the terminal and housing. It transfers and secures the terminal in the cavity through engagement with a corresponding housing feature, providing reliable retention while maintaining structural simplicity.
2Quantity of substance
If the connector uses larger terminal spacing, then manufacturing and assembly are easier, but the signal density is reduced
Solution Approach 1:
The locking feature extends laterally from the terminal's centerline, utilizing the lateral dimension for engagement rather than requiring increased longitudinal spacing. This allows compact terminal arrangement while maintaining manufacturability through standardized processes.
3Reliability
If the terminal locking feature is biased outwardly, then the terminal is securely retained in the cavity, but the insertion force requirement increases
Solution Approach 1:
The spring element is pre-biased to exert outward force on the locking feature before insertion. During insertion, the locking feature is temporarily compressed inward, and upon release, the pre-biased spring automatically engages the terminal with the housing feature, ensuring secure retention.
Data Source
AI summary
In various embodiments, compact connector designs may be provided that have reduced board pitch (e.g., 1.80 mm, 1.50 mm, 1.27 mm, etc.), but are still capable of accommodating large electrical conductors (e.g., 1.4 mm, 1.1 mm, 0.9 mm, etc.). In this manner, PCB footprint may be reduced (e.g., by 50% when a staggered connector configuration is used), while adequate current carrying capacity may be maintained (e.g., 2 A, 3 A, 4 A, etc.). Additionally, or alternatively, one or more other advantages may be achieved, such as ruggedness (e.g., vibration endurance), error proofing, configuration flexibility, ease of manufacturing, ease of assembly, and/or lowered costs.