Sealed PCB Contact Module for Flexible Board Orientation
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Solution Overview
Problem
Existing contact modules for connecting circuit boards or lead frames face challenges in achieving a cost-effective and permanent seal, particularly when orientations and connection types vary, leading to increased complexity and manufacturing costs.
Innovation Solution
A contact module with angled circuit board contacts and a sealing body design featuring a circumferential collar and locking arms, along with an elastically deformable sealing head, allows for flexible orientation and precise positioning, enabling a robust and cost-effective sealing solution. The module includes press-in zones with oblique side flanks and a non-positive connection mechanism for simplified assembly and enhanced sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate solder contact designs are used for each connection type and orientation, then the connection reliability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent implements a universal contact module design where a single basic contact element can be oriented and configured to serve multiple connection types and orientations. The contact element includes a body with a first contact region and a second contact region that can be positioned to accommodate different PCB connection requirements (SMD, single pin, multiple pins) without requiring separate contact designs for each variant.
2Adaptability or versatility
If separate solder contact variants are maintained for different orientations, then the adaptability to various mounting directions is improved, but the loss of time and inventory complexity worsen
Solution Approach 1:
The contact element is designed with dynamic orientability, allowing the same contact component to be positioned at different angles and orientations during assembly. The contact body can be configured to mount perpendicular or parallel to the PCB plane, and the second contact region can be oriented to provide solder connections in various directions, eliminating the need for separate static contact designs for each orientation.
3Object-affected harmful factors
If traditional sealing methods are used for PCB connections, then the protection against environmental influences is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The patent integrates the sealing function directly into the contact element structure itself. The contact element includes an integrated seal that combines the electrical contact function with the sealing function, eliminating the need for separate sealing components or complex sealing processes. This integrated approach provides IP67 protection while simplifying the manufacturing process and reducing costs.
4Reliability
If multiple separate contact designs are used for different connection types, then the connection reliability is improved, but the ease of manufacture worsens
Solution Approach 1:
The contact element is designed as a universal component that can accommodate multiple connection types through a single design. The first contact region can be configured for SMD mounting, single pin, or multiple pins, while the second contact region provides the corresponding solder connection. This eliminates the need to maintain separate contact designs for each connection variant, simplifying manufacturing while maintaining reliable connections.
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a circuit board contact assembly (1) for making contact between a first printed circuit board (PCB1) and a second printed circuit board (PCB2), comprising at least two circuit board contacts (10) which have a connecting portion (11) at one contacting end thereof and a press-in zone (12) at the second contacting end thereof; at least one sealing member (20) which entirely surrounds the contacts in a central portion is provided between the connecting portion (11) and the press-in zone (12), the connecting portion (11) protruding from one lateral surface (21) of the sealing member (20) and the press-in zones (12) protruding from another lateral surface (22) of the sealing member (20).