PCB Plug-in Extension Reduces Insertion Force
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Solution Overview
Problem
Existing solutions for connecting printed circuit boards to backplanes face challenges due to manufacturing tolerances, requiring high contact forces at one end and risking damage to spring contacts at the other, while also being space-inefficient and requiring specialized connectors.
Innovation Solution
A printed circuit board extension with a stepped shape, precision-manufactured contacts, and a compact design that aligns with conductor tracks, reducing insertion forces and accommodating tolerances, and featuring a positioning projection for precise alignment and adjustable impedance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a printed circuit board is plugged directly into a connector, then the connector must ensure sufficiently high contact forces with a circuit board at the lower end of the tolerance, but with a circuit board at the upper end of the tolerances the risk of damage to the spring contacts in the plug part must be prevented and also high insertion forces are to be avoided
Solution Approach 1:
The patent introduces an intermediary component (the plug-in extension made of plastic) between the printed circuit board and the connector. This intermediary absorbs the dimensional variations of the PCB due to manufacturing tolerances, ensuring that the connector always receives a component with consistent dimensions. The plastic extension acts as a buffer that compensates for PCB thickness variations, maintaining reliable contact forces while preventing damage to spring contacts.
2Reliability
If a printed circuit board plug-in extension is used to improve contact force reliability, then contact reliability is improved, but a comparatively large amount of space is required since the printed circuit board plug-in extension surrounds the printed circuit board on both sides
Solution Approach 1:
The patent repositions the contacts from surrounding the PCB on both sides to being arranged in a single plane with the PCB. The contacts are configured to extend from the extension body in a manner that aligns them with the PCB edge, effectively utilizing the same dimensional space as the original PCB-connector interface rather than adding bilateral extensions.
3Reliability
If a printed circuit board plug-in extension is used to improve contact reliability, then contact reliability is improved, but a special plug connector is required to accommodate the plug extension since its thickness is greater than the thickness of the printed circuit board
Solution Approach 1:
The patent designs the plug-in extension with a thickness that allows it to be accommodated by conventional card edge connectors. The extension body is configured to present a mating surface that is compatible with standard connector interfaces, enabling the same connector type to serve both direct PCB connections and connections through the extension, thus achieving multi-functionality.
4Volume of moving object
If the contacts are arranged to traverse the partition once, then the dimensions of the extension are minimized and a compact design results, but the contacts must be precisely positioned to ensure proper alignment with conductor tracks
Solution Approach 1:
The patent incorporates positioning projections on the extension body that engage with corresponding features on the PCB to automatically ensure precise alignment. The extension's geometry itself provides the positioning function, with the body shape and contact arrangement designed to self-align with the PCB edge and conductor tracks, eliminating the need for additional external positioning mechanisms.
Data Source
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AI summary
A printed circuit board connector extension (10) with a body (16, 18) made of plastic, which can be attached to a printed circuit board, with a first and a second group of contacts (26, 27), each having a connecting end (32) for contacting conductor tracks on the printed circuit board and a plug end (28) for contacting contacts of a connector part, wherein the connecting ends (32) of the two groups of contacts (26, 27) are arranged on the same side of the body (16, 18), while the plug ends (28) of the first group are arranged on a different side of the body (16, 18) than the plug ends (28) of the second group.