PCB Edge Connector With Slanted Pins for Zero-Footprint Access
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Solution Overview
Problem
Existing printed circuit boards (PCBs) require large, expensive connectors for external device connections, which occupy valuable space and hinder miniaturization, and existing connectors are not easily removable or manufacturable.
Innovation Solution
A two-part PCB external device connector using moveable, non-linear slanted pins and fixed castellated orifices that frictionally engage to provide a rugged, inexpensive, and compact connection along the edges or arc of the PCB, with an audible and physical indication of a secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large connectors are used for external device connections, then connection reliability is improved, but PCB space occupation increases and manufacturing cost increases
Solution Approach 1:
The connector is divided into two separate parts: a board connector with castellated holes formed on the PCB edge, and a mating connector with corresponding pins. This segmentation allows the connector to occupy minimal PCB space while maintaining reliable electrical connections through the interlocking pin-and-hole configuration.
Solution Approach 2:
The connector design transitions from a traditional planar connector to a three-dimensional configuration where pins extend perpendicular to the PCB surface. The castellated holes are formed along the edge of the PCB, creating a vertical connection profile that reduces the footprint on the PCB while maintaining connection integrity.
2Reliability
If large connectors are used for external device connections, then connection reliability is improved, but manufacturing cost increases
Solution Approach 1:
The castellated holes are self-formed through edge preparation processes (sawing, grinding, or drilling) that are already part of standard PCB manufacturing. The conductive plating is applied during the same plating process used for other PCB features, eliminating the need for separate connector manufacturing steps and reducing overall manufacturing cost.
Solution Approach 2:
The connector features are integrated into the standard PCB manufacturing process flow. The castellated holes are formed and plated simultaneously with other PCB features, and the board connector is created as part of the PCB fabrication itself rather than as a separate component, thereby reducing assembly steps and manufacturing cost.
3Reliability
If traditional connectors are used, then electrical connection is achieved, but the connector occupies valuable PCB real estate and cannot be easily removed
Solution Approach 1:
The connector is designed with movable pins that can be inserted into and removed from the castellated holes. The friction fit provided by the tapered pins allows for easy insertion and removal while maintaining a secure electrical connection during use, enabling dynamic attachment and detachment of external devices.
4Area of stationary object
If compact connector design is implemented, then PCB space is minimized, but connection ruggedness may be compromised
Solution Approach 1:
The connector combines multiple materials and structural features: conductive plating on the castellated holes provides electrical conductivity, the PCB substrate provides mechanical support, and the tapered pins provide both electrical connection and mechanical retention. This composite approach maintains connection ruggedness while minimizing PCB space occupation.
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 a compact, easy-to-manufacture, and cost-effective connection that occupies zero space on the PCB when disconnected, providing secure and efficient electrical engagement with various PCB shapes, while minimizing space usage and manufacturing costs.
Implementation Method 1
moveable, non-linear slanted pins and fixed castellated orifices that frictionally engage
Data Source
AI summary
A two part connector for the temporary connection of an external periphery device to a printed circuit board (PCB). When coding or diagnostics need to be performed on much of todays electronic or electronic controlled equipment, an external unit needs to be physically connected to the microprocessor on the PCB of the equipment. Until now equipment manufacturers either install a socket onto the PCB, or form a mating part of connector directly on the surface of PCB, that is electronically connected to the microprocessor through electrical trace paths. This device eliminates the need for a socket and forms an intermediary element between the external unit and the PCB, that connects to the PCB with a set of vertical pins that matingly connect to a series of cutouts on the PCB. This device connects to a plethora of external devices and takes zero space on the surface of the PCB.