Resilient Contactor for High-Cycle PCB Testing
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Solution Overview
Problem
Conventional connectors for printed circuit boards have a limited number of mating cycles, restricting the ability to test multiple printed circuit boards with a single test board without requiring frequent exchange or replacement of test equipment.
Innovation Solution
A contactor with a multiplicity of electrically conductive contacting means that can be resiliently mounted, allowing for a high number of contacting cycles without wear or damage, and a component receptacle design that facilitates easy insertion and secure attachment of components, enabling repeated testing of printed circuit boards without mechanical or electrical contact with external components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connectors are used for connecting printed circuit boards to test boards, then the connection can be established and disconnected, but the number of mating cycles is limited causing wear and damage
Solution Approach 1:
The patent introduces a contactor as an intermediary device between the printed circuit board and test board. The contactor includes a component receptacle that receives the component and multiple contacting means that establish electrical connections without requiring the connector to be repeatedly mated and unmated. This intermediary structure absorbs the mechanical stress of repeated connections, protecting the original connector from wear and damage while enabling extensive testing cycles.
2Productivity
If connectors are repeatedly mated and disconnected for testing multiple printed circuit boards, then testing can be performed, but the connector durability decreases and equipment exchange is required
Solution Approach 1:
The system is segmented into three distinct parts: the printed circuit board with its connector, the contactor with component receptacle and contacting means, and the test board. This segmentation allows the contactor to serve as a reusable intermediary that remains in place while different printed circuit boards are tested. The connector on the printed circuit board is only mated once with the contactor, while the contactor itself can service multiple boards, thereby extending the effective service life of the connector and increasing overall productivity.
3Reliability
If the component receptacle securely holds the component, then repeated testing is enabled, but the component cannot be easily removed and reinserted
Solution Approach 1:
The contactor employs resilient contacting means that are flexible and capable of dynamic movement. These contacting means can deflect to accommodate component insertion and removal while maintaining secure electrical connections during testing. The resilient nature allows the system to transition between holding the component securely for repeated testing and allowing easy removal when needed, balancing reliability with operational ease.
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 contactor allows for increased durability and repeated testing of printed circuit boards, extending the number of possible contacting cycles and preventing wear or damage, thus enabling efficient and reliable testing of multiple boards without the need for frequent equipment exchange.
Implementation Method 1
The contactor (3) has a multiplicity of contacting means (19a, 19b), which are resiliently mounted and can be displaced along the insertion direction E
Data Source
Figure 1
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Figure 3
AI summary
The contactor (3) has component receptacle (15) into which specific component (7) is inserted along insertion direction (E), and several contacting portions (19a,19b) which are electrically conductive. Each of contacting portions is spaced from the component receptacle along a direction (X) which is perpendicular to the insertion direction. The contacting portions are arranged in an operating position with respect to terminal contact (9a,9b) fixed to specific component placed on the circuit board (5). An independent claim is included for method for contacting secured component on printed circuit board.