User-Replaceable Electrical Connector Isolates Mechanical Stress

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Solution Overview

Problem

Portable electronic devices with soldered external electrical connectors are prone to costly and time-consuming failures due to mechanical forces, such as tipping, which can cause solder joints to fail, requiring expensive and time-consuming repairs.

Innovation Solution

A user-replaceable connection system with a sacrificial portion that fails in a predetermined mode when a minimum failure force is applied, isolating mechanical and electrical stresses from the internal circuit board, allowing easy and cost-effective replacement by end users.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If external electrical connectors are soldered to the circuit board, then the connection is secure and reliable, but the device becomes vulnerable to solder joint failure under mechanical stress and repair becomes costly and time-consuming

Engineering Contradiction:

Improveconnection reliabilityVSAvoidrepair ease

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The connection system is divided into separate components: an external connector assembly that can be independently replaced from the internal circuit board. The mounting element with sacrificial portion acts as a buffer zone, allowing the external connector to be separated and replaced without affecting the circuit board or internal connectors, thus enabling easy repair while maintaining connection reliability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mounting element is designed as a sacrificial component with a predetermined failure mode. When excessive force is applied, the mounting element fails in a controlled manner, protecting the expensive circuit board and internal connectors. This disposable mounting element can be replaced along with the external connector, reducing repair costs and time compared to repairing soldered connections on the circuit board

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If external electrical connectors are soldered to the circuit board, then the connection is stable, but mechanical forces can cause solder joint failure requiring expensive repairs

Engineering Contradiction:

Improveconnection stabilityVSAvoidmechanical stress damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The mounting element with sacrificial portion serves as a pre-designed protective buffer between the external connector and the circuit board. It is engineered to fail in a predetermined failure mode under excessive mechanical force, absorbing the shock and preventing transmission of damaging forces to the circuit board and internal connectors, thus protecting against mechanical stress damage before it can reach critical components

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The mounting element acts as an intermediary component between the external connector and the circuit board. It provides a mechanical interface that isolates the circuit board from direct mechanical stresses applied to the external connector, allowing the connector to be firmly attached while protecting the vulnerable solder joints on the circuit board from harmful forces

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the connector is firmly attached to the circuit board, then the connection is reliable, but repair requires specialized tools and knowledge

Engineering Contradiction:

Improveconnection reliabilityVSAvoiduser replaceability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The connection system is segmented into user-replaceable modules: the external connector and mounting element can be removed and replaced as a unit without requiring access to the circuit board or specialized tools. This segmentation enables end users to perform replacements themselves while maintaining reliable electrical connections through the standardized connector interface

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The design enables self-service repair by end users. The external connector assembly with mounting element is configured to be easily removed and replaced by users without specialized knowledge or tools. The standardized interface and modular design allow users to maintain their own devices, eliminating the need for professional repair services for connector failures

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS8875389B2Method of making an electrical connection system

Publication Date: 2014.11.04 FLEXTRONICS AP LLC

AI summary

Systems and methods electrically connect a first electronic device or electrical component, having a external electrical connector, to a circuit board of a second electronic device. A low-cost, user-installable connection system isolates mechanical stresses imposed on the external electrical connector to within the user-installable connection system, thereby preventing the mechanical stresses from reaching the circuit board in the second electronic device. If the connection becomes faulty, only the low-cost, user-installable connection system must be replaced.