PCB Plug Connector Spring Tabs for Misalignment Compensation
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Solution Overview
Problem
Existing electrical plug connectors for printed circuit boards face challenges in compensating misalignment while maintaining mechanical stability and suitable electrical properties, particularly in high-frequency applications, due to complex designs that are difficult to produce and prone to insufficient mechanical stability.
Innovation Solution
An electrical plug connector featuring an outer conductor contact element with elastic spring tabs and a dielectric support element, where the spring tabs are arranged annularly around the connector's axis, supported laterally by the dielectric element, allowing for lateral displacement to compensate for misalignment without irreversible deformation, and optionally featuring a twisted profile for enhanced contact pressure optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complex turns are used in the contact element to compensate misalignment, then misalignment compensation ability is improved, but manufacturing complexity increases and mechanical stability decreases
Solution Approach 1:
The contact element is divided into multiple spring tabs that are arranged radially around the central axis. Each spring tab can independently deflect to accommodate misalignment, replacing the complex continuous turns with simpler segmented elastic elements that are easier to manufacture while maintaining compensation capability.
Solution Approach 2:
The spring tabs are designed with specific elastic properties to provide dynamic adaptation during connection. The tabs can deflect elastically within their linear range to compensate for misalignment during the plugging process, then return to their original position, providing both adaptability and mechanical stability.
2Adaptability or versatility
If complex turns are used in the contact element, then misalignment compensation is improved, but mechanical stability deteriorates
Solution Approach 1:
By segmenting the contact element into multiple independent spring tabs, each tab provides localized elastic compensation while the overall structure maintains rigidity through the radial arrangement and central support, achieving both adaptability and mechanical stability.
Solution Approach 2:
The contact element combines elastic material properties for the spring tabs with a rigid central structure. The spring tabs are made from elastic material to provide misalignment compensation, while the central support provides mechanical stability, creating a composite structure that achieves both requirements simultaneously.
3Adaptability or versatility
If complex turns are used in the contact element, then misalignment compensation is improved, but production difficulty increases
Solution Approach 1:
The segmented spring tab design allows each tab to be manufactured as a simpler elastic element rather than forming complex continuous turns. The tabs can be attached to a central support in a radial pattern, which is more amenable to standard manufacturing processes and assembly techniques.
Solution Approach 2:
The design changes from complex geometric turns to simple elastic spring tabs with controlled material properties. By adjusting parameters such as tab length, thickness, and material elastic modulus, the compensation capability is achieved through material behavior rather than complex geometry, simplifying manufacturing.
4Adaptability or versatility
If the contact element is made flexible for misalignment compensation, then adaptability is improved, but mechanical stability deteriorates
Solution Approach 1:
The contact element is segmented into flexible spring tabs attached to a rigid central support. The tabs provide the necessary flexibility for misalignment compensation through elastic deflection, while the central support maintains overall mechanical stability and structural integrity during the connection process.
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
The solution provides a mechanically stable and flexible connection capable of compensating radial, rotational, and angular misalignments, while maintaining high-frequency signal transmission capabilities and reducing production complexity.
Implementation Method 1
The deformability or the elasticity of the spring tabs can be chosen in such a way that a sufficient radial contact force can be provided to produce a mechanically stable electrical connection... for the compensation of misalignment described below), but without undergoing an irreversible plastic deformation.
Implementation Method 2
The support element is configured to be displaceable laterally relative to the electrical device (2, 3).
Data Source
AI summary
The invention relates to an electrical plug connector having an outer conductor contact element with a plurality of elastic spring tabs and a dielectric support element. The spring tabs are arranged, with a respective rear end, annularly around the longitudinal axis (L) of the plug connector and are fastened indirectly or directly to an electrical device. It is provided that the spring tabs are supported with a respective front, free end section laterally on the dielectric support element, wherein the dielectric support element is displaceable laterally relative to the electrical device.