PCB Connector Assembly With Snap-Fit Leaf Spring Contacts
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Solution Overview
Problem
Existing connection methods for printed circuit boards require manual handling, high forces, or specialized equipment for connection and disconnection, and often involve costly mechatronic parts, making them inefficient and costly.
Innovation Solution
A printed circuit board-and-plug arrangement featuring a plug housing with an embedded metal strip or wire that forms a leaf spring or spring element, allowing for easy connection and disconnection by pushing and pulling, with a snap-action mechanism for secure engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a standard connection system for printed circuit boards is used, then the connection is releasable, but manual handling is required and two mechatronic parts per connection are needed, increasing costs
Solution Approach 1:
The patent combines the plug and housing into a single integrated component where the contact elements are directly formed as integral parts of the housing structure. This eliminates the need for separate mechatronic parts while maintaining the releasable connection capability through the snap-fit mechanism with elastic deformation of the housing material.
2Device complexity
If a printed circuit board edge connector is used, then the plug is integrated into the printed circuit board, but certain requirements are placed on the surface material and gold plating is commonly required, increasing costs
Solution Approach 1:
The patent employs standard copper traces and conventional PCB materials instead of expensive gold-plated edge connectors. The connection is achieved through mechanical insertion with elastic deformation of the housing, eliminating the need for costly surface treatments while maintaining functional reliability.
3Ease of operation
If a fork contact is used, then the connection can be simply pressed into place, but disconnection of the connection can be difficult due to the connection forces typically observed, introducing stress into the solder or press-fit connections
Solution Approach 1:
The patent incorporates an elastic deformation mechanism in the housing material that allows dynamic adjustment during connection and disconnection. The housing elastically deforms to accommodate the contact elements, enabling easy insertion and removal without generating excessive stress on the PCB solder or press-fit connections.
4Force
If a SKEDD connector is used, then the interface is simple and requires low connection forces, but disconnection of the connection requires manual handling or manipulation that requires special equipment
Solution Approach 1:
The patent designs a snap-fit mechanism where the elastic housing material automatically engages with the contact elements upon insertion and can be easily released by applying minimal force in the opposite direction. This self-service mechanism eliminates the need for special disconnection equipment while maintaining low connection forces throughout the operation.
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 cost-effective, easy-to-handle connections with minimal force, facilitating multiple cycles without stress on solder or press-fit connections, and allowing for a simple, uncomplicated board design.
Implementation Method 1
a metal strip or metal wire (2a-c) is embedded in the insulating material of the plug housing (1) in such a way that at least a portion (2b-f) of the metal strip or the metal wire protrudes into the opening (7)
Data Source
AI summary
A printed circuit board-and-plug arrangement comprises a printed circuit board from which at least one electrically conductive contact lug which is electrically connected to at least one conductor track of the printed circuit board protrudes, and a plug housing composed of insulating material, which plug housing has at least one opening, wherein a metal strip or metal wire is embedded in the insulating material so that at least a portion of the metal strip or the metal wire protrudes into the opening, wherein the plug housing is releasably connected to the printed circuit board so that the contact lug is inserted into the opening and thereby comes into contact with the portion, wherein the longitudinal direction of the contact lug and the longitudinal direction of the portion run perpendicularly in relation to one another.