PCB Terminal Connector Assembly for Dense Signal Routing
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Solution Overview
Problem
In automation technology, achieving high packing density and clear signal routing between control systems and field devices with numerous single-wire wirings is challenging, especially in terms of signal assignment and connection complexity.
Innovation Solution
A plug connector arrangement featuring a marshalling connector with spring connections and metal pins that are electrically and cohesively connected to a circuit board, allowing for flexible and cost-effective signal routing with reduced single-wire wiring needs, and enhanced robustness against external influences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If individual conductor routing with terminal blocks is used, then clear signal assignment is achieved, but device complexity and space requirements increase
Solution Approach 1:
The patent combines multiple individual terminal blocks into a single integrated connector assembly with a common housing and base plate. Multiple contact terminals are arranged in rows on the base plate, eliminating the need for separate terminal blocks for each conductor while maintaining clear signal routing through structured contact arrangements.
Solution Approach 2:
The connector assembly serves multiple functions within a single device: it provides structured cable access through multiple cable openings, maintains organized conductor routing via the base plate structure, ensures reliable electrical connections through spring contacts, and enables clear signal assignment through positional correspondence between cable positions and contact terminals.
2Area of stationary object
If packing density of single-wire wiring is increased, then space efficiency improves, but signal separation and assignment clarity deteriorate
Solution Approach 1:
The connector assembly segments the wiring space into distinct cable openings and corresponding contact terminal positions. Each cable opening is spatially associated with specific contact terminals through the structured base plate arrangement, maintaining signal separation even when multiple cables are connected in close proximity.
Solution Approach 2:
The patent utilizes a two-dimensional arrangement of contact terminals on the base plate with multiple rows and columns, allowing high packing density in the planar view while maintaining clear spatial correspondence between cable openings and contacts. The vertical dimension is also utilized through the spring contact mechanism that engages with terminals from above.
3Reliability
If standardized connectors with spring connections are used, then connection reliability improves, but manufacturing complexity increases
Solution Approach 1:
The patent integrates multiple spring contact mechanisms into a single molded housing structure. The spring contacts are pre-positioned and pre-assembled on a base plate during the molding process, eliminating the need for separate assembly steps for each spring contact while maintaining the reliable spring connection mechanism.
Solution Approach 2:
The connector assembly is designed to be self-assembling through the injection molding process. The housing, base plate, and spring contacts are formed and positioned in a single manufacturing step, with the spring contacts automatically engaging with the base plate terminals through elastic deformation during the molding cycle, reducing manual assembly requirements.
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
This solution enables flexible signal routing, cost savings, and robust connections with high packing density, simplifying manufacturing and ensuring clear signal separation and assignment, while being resistant to external impacts.
Implementation Method 1
a plug connector, in particular a series connector, having a number of spring terminals
Data Source
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AI summary
The invention relates to a terminal connector (100) for connecting a number of spring connections (104) of a plug connector (102) to the amount of contact connections (108) of an interface module (106), with a printed circuit board (110) having a lower side (111) and an upper side (112), and a number of strip conductors (114), wherein each strip c1onductor (114) is electrically connectable to a contact connection (108) of the interface module (106); a number of metal pins (116), wherein each metal pin (116) is connected in an electrically conductive and integrally bonded manner to a strip conductor (114) of the printed circuit board (110), wherein the metal pins (116) extend from the lower side (111) of the printed circuit board (110) and are insertable into the spring connections (104) of the plug connector (102).