PCB Contact Element Housing for Tolerance-Compensating Alignment
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Solution Overview
Problem
Existing contacting systems for electronic assemblies on printed circuit boards face issues with precise positioning and tolerance-related deviations, leading to production interruptions, downtime, and manual rework, especially in automated processes.
Innovation Solution
A contacting system with deformable contact elements enclosed in a housing made of electrically insulating material, featuring a deformable area and positioning elements, allowing for self-adjustment and alignment of contact elements to compensate for positional and size deviations, ensuring reliable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If contact elements are used without deformable areas, then manufacturing precision can be maintained, but positioning accuracy deteriorates due to tolerance deviations
Solution Approach 1:
The contact element incorporates a deformable area that changes its mechanical properties (flexibility) to compensate for positional deviations. This allows the contact element to adapt its shape and position within a range, maintaining reliable contact despite manufacturing tolerances in the electronic assembly or PCB.
Solution Approach 2:
The contact element transitions from a rigid structure to a dynamic structure with a deformable area that can flex and adapt. This dynamic capability allows the contact element to self-adjust to positional variations, ensuring reliable electrical connection without requiring extremely tight manufacturing tolerances.
2Reliability
If deformable contact elements are used, then positioning accuracy improves, but device complexity increases due to housing and positioning elements
Solution Approach 1:
The housing and positioning elements are integrated into a single unit that combines multiple functions: electrical insulation, mechanical support, and precise positioning. This merging reduces the number of separate components and simplifies the overall assembly process despite the added functionality.
Solution Approach 2:
The housing serves multiple purposes simultaneously: it provides electrical insulation between conductive parts, mechanically supports the deformable contact element, and incorporates positioning elements for precise alignment. This multi-functionality reduces the need for separate components and simplifies the overall system.
3Reliability
If positioning elements are added to the housing, then manufacturing precision deteriorates due to additional components, but positioning accuracy improves
Solution Approach 1:
The positioning elements are pre-integrated into the housing during manufacturing, establishing precise geometric relationships between the housing and positioning elements before final assembly. This preliminary positioning ensures that when the housing is assembled to the electronic assembly, the contact elements are automatically aligned with the PCB contact points, compensating for tolerances.
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
Enables reliable and efficient electrical connections between electronic assemblies and printed circuit boards, reducing production disruptions and costs by allowing for automated and manual processes to adapt to tolerances.
Implementation Method 1
the at least one contact element has a deformable area between the first end and the second end in a direction parallel to the electronic assembly and the PCB, in order to achieve a displacement of the first end relative to the second end of the contact element
Data Source
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AI summary
Contacting system (1) for contacting an electronic assembly (CA) with a printed circuit board (PCB), comprising at least one contact element (2) with a first and second end (3, 4) for connection with the electronic assembly (CA) or printed circuit board (PCB), wherein the contact element (2) has a deformable area (5) between the first and second end (3, 4) in a direction parallel to the electronic assembly (CA) and printed circuit board (PCB), and a measuring resistor (20) with a contacting system (1).According to the invention, the at least one contact element (2) is surrounded by an enclosure (6) made of electrically insulating material, which enclosure (6) is designed to fix the first or second end (3, 4) of the contact element (2) and is displaceable in a direction parallel to the electronic assembly (BG) and the printed circuit board (PCB), wherein at least one positioning element (7) projecting beyond the first or second end (3, 4) of the contact element (2) is arranged on the enclosure (6) for arrangement in at least one positioning opening (PO) in the printed circuit board (PCB) or electronic assembly (BG).