Plug Connector Alignment Plate Whisker Containment
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Solution Overview
Problem
Electrical and electronic modules with plug connectors face issues of progressive whisker growth and loose particles causing short-circuit bridges due to mechanical stress, requiring a reliable alignment and positioning method for lead wires to ensure fault-free connections with circuit carriers.
Innovation Solution
A plug connector design featuring a positioning and alignment plate with guide openings and latching connections, which holds the connector body in place, preventing whisker growth and mechanical damage, and allows for precise alignment and secure locking positions to maintain contact integrity during assembly and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If press-in pins are used to connect conducting wires to circuit carrier, then electrical connection is achieved, but mechanical stress causes progressive whisker growth and loose particles leading to short-circuit bridges
Solution Approach 1:
The patent introduces an insulating body with hollow-cylindrical bores as an intermediary structure between the press-in pins and the circuit carrier. This insulating body serves as a mediator that contains the pins while preventing whisker growth and particle loosening from causing short-circuits, thus resolving the contradiction between achieving electrical connection and preventing harmful effects.
Solution Approach 2:
The patent converts the harmful effect of whisker growth by providing hollow-cylindrical bores that contain and isolate whiskers and loose particles. Instead of allowing these harmful factors to cause short-circuits, the structure channels and confines them within the hollow bores, transforming a potential failure mode into a controlled containment system.
2Reliability
If hollow-cylindrical bores are used to limit whisker growth space, then short-circuit risk is reduced, but the flat surface and contact surface require very high degree of flatness
Solution Approach 1:
The patent transitions from requiring two-dimensional surface flatness to achieving three-dimensional cavity containment. By creating hollow-cylindrical bores that extend vertically, the design shifts the precision requirement from the horizontal flatness of surfaces to the vertical integrity and alignment of the cylindrical cavities, thereby reducing the stringent flatness requirements while maintaining gap-free containment.
Solution Approach 2:
The insulating body with pre-formed hollow-cylindrical bores is prepared in advance, creating the containment structure before the pins are inserted and before whisker growth occurs. This preliminary preparation of the containment geometry eliminates the need for high post-assembly surface flatness, as the three-dimensional cavities provide inherent gap-free containment.
3Manufacturing precision
If positioning and alignment plate is used to orient conducting wires, then alignment precision is improved, but additional components increase device complexity
Solution Approach 1:
The insulating body performs multiple functions simultaneously: it provides structural support for the press-in pins, creates hollow-cylindrical bores for whisker containment, and incorporates positioning/alignment features for the conducting wires. By integrating these multiple functions into a single component, the patent achieves precise wire alignment without proportionally increasing device complexity.
Solution Approach 2:
The patent merges the alignment plate function with the insulating body structure. Instead of adding a separate alignment plate as an additional component, the alignment features are integrated directly into the insulating body, combining the functions of insulation, pin support, whisker containment, and wire alignment into a unified multi-functional component.
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 ensures process-reliable alignment and positioning of lead wires, preventing whisker growth and mechanical damage, thus ensuring fault-free and vibration-resistant electrical connections, allowing for efficient assembly and operation of electrical modules.
Implementation Method 1
The positioning and/or alignment plate comprises at least one spring element on the side facing the contact connection scheme, which is designed to brace the positioning and/or alignment plate in the at least one locking position against the circuit carrier by means of spring force
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
The present invention relates to a plug connector for connection to a circuit carrier, comprising at least one electrically insulating plug body. The plug body has a multiplicity of conducting wires distanced from one another in a pattern arrangement. By means of one of the ends thereof, the conducting wires form a plug contact schema for electrically contacting or connecting to a mating plug. By means of the opposite ends of the conducting wires, a connection contact schema for corresponding contact points of the circuit carrier is formed in turn. The conducting wires, at least on the side of the connection contact schema, are oriented in their arrangement relative to one another by a positioning and/or orientation plate in that the positioning and/or orientation plate has parallel guide openings, which are each penetrated by a conducting wire with play. At least one detent connection is formed by the plug body and the positioning and/or orientation plate, by means of which detent connection the plug body and the positioning and/or orientation plate are held in at least one detent position.