PCB Socket Contact Tongues Tolerance Compensation
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Solution Overview
Problem
Existing sockets for printed circuit boards face challenges in providing reliable and versatile plug connections that can accommodate tolerance variations and are easy to connect, while also being cost-effective and simple in design.
Innovation Solution
A socket design featuring contact tongues that converge and are formed on a sheet metal ring, allowing for tolerance compensation and easy attachment to printed circuit boards, with an optional outer sleeve for protection and stability, and attachment means such as legs for secure mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact tongues are made rigid to ensure stable electrical connection, then connection reliability improves, but tolerance compensation capability deteriorates
Solution Approach 1:
The contact element is divided into multiple independent contact tongues separated by slots, allowing each tongue to move independently to compensate for tolerances while maintaining stable electrical connection through the collective action of all tongues
Solution Approach 2:
The contact tongues are designed with dynamic characteristics, allowing them to deflect and adapt to position variations of the connector pin, thereby compensating for manufacturing tolerances while maintaining reliable electrical contact
2Adaptability or versatility
If socket is designed as multi-part assembly to improve functionality, then adaptability improves, but device complexity increases
Solution Approach 1:
The contact element and outer sleeve are combined into a single integrated component manufactured from one piece of sheet metal, reducing part count and assembly complexity while maintaining the functional benefits of having both contact tongues and protective sleeve
Solution Approach 2:
The single integrated component serves multiple functions: the contact tongues provide electrical connection and tolerance compensation, while the outer sleeve provides protection and structural support, eliminating the need for separate parts
3Ease of manufacture
If conventional sheet metal stamping is used for production, then manufacturing simplicity improves, but manufacturing precision deteriorates
Solution Approach 1:
The contact tongues are pre-formed with their final converged shape and the slots are pre-cut during the stamping process itself, eliminating the need for subsequent precision machining operations and achieving both manufacturing simplicity and adequate precision
Data Source
Figure 1~4
Figure 5~7
AI summary
The socket has a fitting unit (10) mechanically and electrically connecting the socket with printed circuit boards. A number of contact guides (4) are separated from each other by longitudinal slots (7) and surrounds a connecting passage. The contact guides converge in a direction of a free end (8) of the guides. The contact guides are formed at a closed sheet metal ring (1). The fitting unit is formed at a side turned to the contact guides. The fitting unit is formed as individual contact pins (5) that are separated by slots (9).