Right Angle Electrical Connector With Flexible Circuit
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Solution Overview
Problem
Miniaturized electrical connectors face challenges with increased precision in positioning and connection due to high input/output density, leading to issues with co-planarity, signal integrity, and skew caused by compliant pins requiring large plated holes and non-symmetric forces during assembly.
Innovation Solution
A right angle electrical connector assembly featuring a flexible circuit with standoff ribs and a stiffener, ultrasonic welding, and an array connector, which ensures precise alignment and attachment to a circuit board, maintaining uniform path lengths and impedance while allowing for easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If compliant pins are used to provide electrical connections to the printed circuit board, then the connector can be assembled, but large diameter plated thru holes are required which adversely affect signal integrity
Solution Approach 1:
The patent removes the compliant pins from the connector assembly entirely, extracting the problematic element that caused signal integrity issues. The flexible circuit board directly provides electrical connections to the printed circuit board without intermediate compliant pins, eliminating the need for large plated thru holes and associated anti-pads that degraded signal integrity.
Solution Approach 2:
The flexible circuit board serves as an intermediary between the array connector and the printed circuit board. Instead of using compliant pins as the connecting medium, the flexible circuit board with its fusible conductive elements provides the electrical connection path, mediating the interface while maintaining signal integrity.
2Productivity
If array connectors are used to provide high-density two-dimensional array of contacts, then I/O density is increased, but alignment and inspection become difficult
Solution Approach 1:
The patent transitions from a planar array connector layout to a three-dimensional configuration using a flexible circuit board that bends at right angles. This dimensional change allows the high-density contact array to be positioned vertically relative to the printed circuit board, improving accessibility for alignment and inspection while maintaining high I/O density.
Solution Approach 2:
The connector is segmented into distinct functional portions: the array connector portion with the two-dimensional contact array, the flexible circuit board that provides structural support and routing, and the connection interface with the printed circuit board. This segmentation allows each portion to be optimized independently for its specific function.
3Reliability
If multiple thru holes are formed in the printed circuit board to accommodate contact tails, then electrical connections are established, but the board structure is weakened and assembly complexity increases
Solution Approach 1:
The patent merges multiple electrical connection functions into a single flexible circuit board interface. Instead of requiring multiple separate thru holes in the printed circuit board for different contact tails, the flexible circuit board consolidates these connections through its fusible conductive elements that attach to conductive pads on the board, reducing PCB structural complexity.
Solution Approach 2:
The patent replaces the mechanical insertion system of compliant pins into plated thru holes with a fusible bonding system. The fusible conductive elements on the flexible circuit board are bonded to conductive pads on the printed circuit board through heating, eliminating the need for mechanical thru hole structures and associated assembly complexity.
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 effectively addresses the challenges of miniaturization by ensuring precise alignment and attachment, maintaining signal integrity, and reducing skew, while accommodating high-density connectors with improved ease of assembly and reduced mechanical stress.
Implementation Method 1
heating the fusible conductive elements to melt and form electrical connections
Implementation Method 2
ultrasonic welding
Data Source
AI summary
A right angle electrical connector assembly includes a connector frame including a plurality of posts, each of the plurality of posts including at least one standoff rib extending therefrom, a flexible circuit having a first end portion and a second end portion, the second end portion being arranged to be connected to a circuit board. The flexible circuit includes a plurality of holes arranged to correspond to the plurality of posts, each of the plurality of posts is received in a respective one of the plurality of holes, and a height of a first major surface of the second end portion of the flexible circuit is set by the at least one standoff rib of each of the plurality of posts.