Self-Registered Connectors for Curved Device Enclosures
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Solution Overview
Problem
Aligning multiple connector receptacles on a device with a curved or non-planar surface is challenging due to the difficulty in aligning pins with corresponding holes in a printed circuit board and openings in the device enclosure.
Innovation Solution
A connector assembly with modular design, using alignment pins and registration features like standoffs and lips, ensures accurate alignment of multiple connector receptacles both within modules and with the device enclosure, even on non-planar surfaces, by employing a main insert mold and additional alignment mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple connector receptacles are placed on a device with a curved or non-planar surface, then the device can communicate with multiple devices simultaneously, but aligning pins with corresponding holes in the printed circuit board and openings in the device enclosure becomes difficult
Solution Approach 1:
The device enclosure is divided into multiple segments or modules, each containing a subset of connector receptacles. Each module can be aligned and assembled independently, making it easier to manage the alignment of pins with openings on curved surfaces. The segmentation allows for modular assembly where each module's alignment requirements are simplified compared to aligning all connectors simultaneously on a curved surface.
Solution Approach 2:
Alignment features such as registration pins, guide slots, or intermediary alignment structures are introduced between the connector receptacles and the printed circuit board openings. These intermediary elements serve as mediators that facilitate precise alignment by providing mechanical guidance and reference points, making the alignment process more manageable on curved surfaces.
2Adaptability or versatility
If multiple connector receptacles are placed on a device, then the device can support multiple interfaces, but the complexity of aligning and registering the connector receptacles increases
Solution Approach 1:
Multiple connector receptacles are merged into integrated modules or assemblies where the alignment and registration features are combined into a single unit. By merging the receptacles with their alignment features into modular assemblies, the overall complexity is reduced as these pre-aligned modules can be installed as complete units rather than individually aligning each connector.
Solution Approach 2:
Alignment features and registration structures are pre-installed or pre-positioned on the device enclosure or printed circuit board before the connector receptacles are attached. This preliminary action establishes reference points and alignment guides in advance, simplifying the subsequent attachment process and reducing the complexity of aligning multiple connectors during final assembly.
3Shape
If connector receptacles are aligned to openings on a curved surface, then the device can accommodate the curved design, but the alignment precision between pins and openings deteriorates
Solution Approach 1:
The alignment system incorporates features that operate in additional dimensions beyond the curved surface plane. For example, alignment pins may extend in the radial direction perpendicular to the curved surface, or registration features may engage in multiple directions simultaneously. This multi-dimensional approach allows the connectors to be precisely aligned despite the curved surface geometry.
Solution Approach 2:
The curved surface is treated with local quality variations, where specific regions contain flat or planar zones around each connector opening, or where the curvature is intentionally modified locally to facilitate alignment. This allows the overall curved design to be maintained while creating localized areas that enable precise pin-to-opening alignment for each connector receptacle.
Data Source
AI summary
Connector receptacles may be provided, where a multiple of such connector receptacles may be readily aligned to openings in a device enclosure, particularly where the openings are located on a curved or otherwise non-planar surface of the device enclosure. One example may provide a connector assembly that includes a plurality of connector receptacles. The connector receptacles in a connector assembly may be accurately aligned or registered to each other, and the connector assembly may be accurately aligned to a device enclosure. In this way, several connector receptacles may be accurately aligned to openings in the device enclosure. In another example, two or more connector receptacles may have faces that are at an oblique angle relative to each other.