Press-fit Plug for Stacked PCB Electrical Connection

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Solution Overview

Problem

Existing lighting devices with multiple printed circuit boards face high production costs and inflexibility due to the need for soldered connections, especially with metal-core boards, which limits flexibility and thermal management.

Innovation Solution

A plug-in connection element with a press-fit design allows for electrical conductivity between circuit boards without soldering, using an electrically insulating covering to prevent electrical contact and a non-rotationally symmetrical cross-section for secure orientation, enabling a compact and space-saving connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If soldered connections are used to connect printed circuit boards, then electrical connection reliability is improved, but production cost increases and manufacturing complexity increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the soldering process (thermal/mechanical system) with a press-fit mechanical connection system. The press-fit plug inserts into a socket to establish electrical contact through direct mechanical pressure, eliminating the need for soldering while maintaining reliable electrical connection between circuit boards.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a press-fit plug and socket as intermediary components to establish electrical connections between circuit boards. These connectors serve as mediators that simplify the connection process compared to direct soldering, reducing manufacturing complexity while maintaining connection reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If soldered connections are used to connect printed circuit boards, then electrical connection reliability is improved, but device flexibility decreases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoiddevice flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent segments the electrical connection system into separate, detachable components (press-fit plug and socket) rather than creating a permanent soldered bond. This segmentation allows the circuit boards to be separated and reconfigured, enhancing device flexibility while maintaining connection reliability when assembled.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The press-fit connection provides a dynamic, reversible connection system that allows for assembly and disassembly, unlike the static permanent connection of soldering. This enables the device to be reconfigured, repaired, or adapted for different uses while maintaining reliable electrical contact when connected.

Inventive Principle:

Principle #15Dynamics

3Volume of moving object

If multiple printed circuit boards are arranged one above the other, then space utilization is improved, but connection complexity increases

Engineering Contradiction:

Improvespace utilizationVSAvoidconnection complexity

Core Design Contradiction:

Volume of moving objectVSDevice complexity

Solution Approach 1:

The patent combines the electrical connection function with the mechanical mounting function into a single integrated press-fit connector system. The press-fit plug and socket simultaneously provide mechanical support for stacking circuit boards and establish electrical connections, reducing overall connection complexity compared to separate mounting and wiring systems.

Inventive Principle:

Principle #5Merging (Combining)

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 simplifies the electrical connection process, reduces production costs, enhances thermal management, and provides a flexible and secure connection method, allowing for precise positioning and easy assembly while avoiding thermal stress and complex mechanical fastening.

Implementation Method 1

the plug-in connection element being designed as a press-fit plug on at least one side

Methodology Applied

Scientific EffectPress-fit connection: Mechanical Fastener

Implementation Method 2

at least one first printed circuit board of the at least two printed circuit boards has at least one electrically conductive area that extends over significant areas of the printed circuit board

Methodology Applied

Scientific EffectElectrical insulation: Electrical Resistance

Implementation Method 3

these components are preferably arranged on printed circuit boards that conduct heat well, such as metal-core printed circuit boards

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP2347639B1Illumination device comprising two printed circuit boards

Publication Date: 2013.02.27 OSRAM GMBH

Figure 1~3b
Figure 2
Figure 4a~4b

AI summary

The invention relates to an illumination device (9) comprising at least one light source, in particular at least one light-emitting diode (LED) (11a), and also at least two printed circuit boards (6, 10) which are arranged at least in part one above another and preferably approximately parallel. According to the invention, the at least two printed circuit boards (6, 10) are connected by means of at least one plug connection element (1), wherein the plug connection element (1) is embodied as an interference-fit plug (2) on at least one side.