Miniaturized Electrical Connector Using Multilayer PCB Windings

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Solution Overview

Problem

Existing electrical connectors in mobile devices face challenges in miniaturization due to the mechanical constraints of metal blades and the need for additional components to associate functions, which limits their size reduction and integration within compact electronic devices.

Innovation Solution

The use of multilayer printed circuit boards with spacers and integrated circuit chips to create a compact electrical connector element, where contact zones on the boards connect directly to the connector's contact zones, eliminating the need for external components and allowing for reduced dimensions and increased functionality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If metal blades are used as contacts in electrical connectors, then reliable electrical connection is achieved, but the connector dimensions cannot be reduced due to mechanical constraints requiring minimum blade width of 100 μm and separation of 150 μm

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidconnector element size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent replaces the mechanical metal blade contact system with an electrical field-based contactless power transfer system. The first element includes a primary winding and the second element includes a secondary winding, enabling electromagnetic induction-based power transfer without physical metal contact, thereby eliminating the mechanical dimension constraints of traditional blade connectors.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the fundamental operating parameter from mechanical contact to electromagnetic field interaction. By using inductive coupling between primary and secondary windings, the system achieves power transfer without the physical constraints of metal blade dimensions, allowing significant reduction in connector size while maintaining reliability through field-based coupling.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If additional components such as common mode filters are mounted around the connector to associate functions, then functional versatility is improved, but the overall device size increases

Engineering Contradiction:

Improveconnector functionalityVSAvoiddevice size

Core Design Contradiction:

Adaptability or versatilityVSVolume of moving object

Solution Approach 1:

The patent integrates multiple functions into the connector structure itself rather than using separate mounted components. The insulating body incorporates guide pins for alignment, the windings provide power transfer and filtering functions, and the overall structure integrates mechanical and electrical functions, eliminating the need for additional external components and reducing overall device size.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connector elements are designed to perform multiple functions within a single integrated structure. The primary and secondary windings provide both power transfer and electromagnetic filtering, the insulating body provides structural support and alignment features, and the guide pins ensure proper positioning, making the connector a multi-functional component that reduces the need for separate dedicated parts.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If the cavity of the first connector element accommodates the projecting portion of the complementary element, then proper contact alignment is achieved, but the connector requires larger dimensions to accommodate the mechanical fitting features

Engineering Contradiction:

Improvecontact alignment precisionVSAvoidconnector element size

Core Design Contradiction:

Manufacturing precisionVSVolume of moving object

Solution Approach 1:

The patent replaces mechanical alignment and fitting features with electromagnetic field-based coupling. The primary and secondary windings are positioned to achieve proper alignment through field coupling rather than mechanical interfitting, eliminating the need for large cavities and projecting portions while maintaining precise alignment through electromagnetic induction principles.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 the production of miniaturized electrical connectors with smaller contact areas and integrated functions, such as filters or overvoltage protection, reducing the size of the printed circuit board and enhancing mechanical strength, suitable for use in mobile electronic devices.

Implementation Method 1

The first element comprises a primary winding and the second element comprises a secondary winding

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP3076770B1Electrical connector

Publication Date: 2023.02.15 STMICROELECTRONICS (TOURS) SAS

Figure 1A~1B
Figure 2A~2B
Figure 3A~4

AI summary

The invention relates to an electrical connector element of the type comprising a frame (47) delimiting an elongated open cavity (49), having two large parallel sides provided with contact areas (61A, 61B) suitable for cooperating with contact areas of a complementary electrical connector element, in which each large side is made up of a multilayer printed circuit board (51, 53).