PCBA Adapter Interface With Curved Disc Spring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Modular test fixtures for printed circuit board assemblies (PCBAs) often suffer from breakage during adapter module insertion due to mechanical stress, leading to costly repairs and production disruptions, especially in high-volume manufacturing environments where precise alignment is not rigorously maintained.
Innovation Solution
An improved interface for the adapter module and test fixture featuring oblong centering holes and chamfered lips that reduce force on alignment features, allowing for angled insertion without sacrificing alignment accuracy, and incorporating a curved disc spring for movement flexibility, thereby minimizing wear and breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If adapter modules are inserted at an angle into a universal receiver, then ease of operation is improved, but reliability deteriorates due to breakage of alignment features
Solution Approach 1:
The patent applies beforehand cushioning by providing a curved disc spring between the receiver-side interface and the housing. This spring anticipates and absorbs the mechanical stress and misalignment forces that occur during angled insertion, preventing these forces from reaching and damaging the alignment features (centering holes and posts) of the multi-pole electrical interface connectors. The spring acts as a protective element that cushions the system against operational errors.
2Strength
If hole liners are added to alignment features, then strength is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts and removes the unnecessary alignment features (centering holes and posts) from the multi-pole electrical interface connectors by providing a curved disc spring that enables angled insertion without requiring these features. This eliminates the need for complex hole liners while maintaining strength and reliability. The solution takes out the problematic elements rather than adding reinforcements to them.
3Device complexity
If alignment features are omitted from multi-pole electrical interface connectors, then device complexity is reduced, but manufacturing precision deteriorates due to increased wear
Solution Approach 1:
The curved disc spring acts as an intermediary element between the adapter module and the receiver-side interface. It mediates the alignment process during angled insertion, ensuring that the multi-pole electrical interface connectors maintain proper alignment without requiring complex alignment features. The spring provides the necessary guidance and tolerance compensation, preserving manufacturing precision while simplifying the overall interface design.
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 significantly reduces the risk of breakage during insertion, maintains alignment accuracy, and avoids the need for costly metal reinforcements, enhancing the operational life and efficiency of the interface and test fixture.
Implementation Method 1
incorporating a curved disc spring for movement flexibility
Data Source
AI summary
Systems for interfacing a printed circuit board assembly (PCBA) adapter module to a receiver housing are provided. The receiver housing may have a first interface mounted on the receiver housing via a first mount and the PCBA adapter module may have a second interface mounted on the adapter module via a second mount. One of the interfaces has a protruding feature that aligns the interfaces when matingly engaged, while the other interface has a centering hole opposite the protruding feature. The first centering hole is enlarged with respect to an axis of an insertion-angle plane such that the protruding feature substantially clears the centering hole without causing either interface to exceed a limit of free-play between that interface and its respective mount.