Self-Aligning Electrical Connector Assembly for IMU Shock Isolation
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Solution Overview
Problem
Existing methods for attaching an inertial management unit (IMU) package connector to an IMU package are labor-intensive and costly, and can fail due to environmental factors, leading to reduced reliability and susceptibility to vibration and shock.
Innovation Solution
A package design featuring beveled sidewalls and recesses in the payload package electrical connector and package body, allowing for self-alignment and secure attachment without screws or solder, using an internal electrical connector to isolate the payload from shocks and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the IMU package connector is attached to the package with adhesive, then the connection is simple and low-cost, but the attachment may fail due to environmental factors such as thermal expansion, salt, or acid
Solution Approach 1:
The patent introduces an intermediate mechanical structure (the package body with recess and the connector with protrusion) that mediates between the connector and the package. This mechanical interface provides reliable attachment while isolating the connector from direct environmental exposure, resolving the contradiction between simple adhesive attachment and reliable environmental resistance
Solution Approach 2:
The patent replaces the chemical bonding mechanism (adhesive) with a mechanical interlocking system consisting of a recess in the package body and a protrusion on the connector. This mechanical substitution provides reliable attachment that is resistant to environmental factors while maintaining manufacturing simplicity
2Reliability
If the IMU package connector is attached to the package with screws, then the connection is secure and reliable, but the package size increases to facilitate screw insertion
Solution Approach 1:
The patent employs a nested structure where the connector protrusion fits into a recess within the package body. This nesting approach provides secure mechanical attachment similar to screws but within a compact footprint, eliminating the need for larger package dimensions required for screw insertion
Solution Approach 2:
Instead of extending outward with screws that require insertion space, the patent inverts the attachment approach by having the connector protrude inward into a recess. This inversion achieves secure mechanical attachment while minimizing package volume requirements
3Strength
If the IMU package connector is soldered or welded to the PCB, then the electrical connection is strong, but repeated forces reduce reliability and the direct mechanical connection increases susceptibility to vibration and shock
Solution Approach 1:
The patent segments the electrical connection system into separate functional components: the electrical conductors provide electrical connectivity while the mechanical interlocking structure (protrusion and recess) provides structural support and shock isolation. This segmentation allows each component to optimize its function without compromising the other under vibration and shock
Solution Approach 2:
The patent introduces a mechanical intermediary structure (the package body with recess and connector with protrusion) that acts as a buffer between the electrical conductors and external forces. This intermediary provides strong electrical connection while isolating the conductors from repeated forces and vibrations, preventing reliability degradation
4Ease of manufacture
If adhesive or screws are used for attachment, then the connector can be attached to the package, but the process is labor intensive and costly
Solution Approach 1:
The patent designs a self-aligning mechanical interlocking system where the protrusion on the connector automatically fits into the recess in the package body during assembly. This self-service mechanism eliminates the need for labor-intensive adhesive application or screw installation, significantly improving assembly productivity while maintaining attachment capability
Data Source
Figure 1A~1B
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AI summary
A package of a payload (or payload package) includes a payload package electrical connector, a first package portion, and a second package portion. The first and second package portions form a body of the payload package. The payload package electrical connector, e.g., a body thereof, and one of the first and second package portions each have at least one beveled sidewall which are configured to abut one another. Optionally, a payload, e.g., an inertial measurement unit, is further configured to be mounted in the payload package, e.g., in the payload package body, for example on one of the first or second package portions. The design of such payload package results in a payload package which is durable, compact, cost effective, and which facilitates self alignment of a payload package electrical connector to the body of the payload package. Further the payload is better isolated from shock and vibration.