Sliding Board-End Connector for PCB Spacing Tolerance

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Solution Overview

Problem

Conventional board-end connectors for photovoltaic inverters face challenges in accommodating varying spacings between the PCB and mounting panel, leading to pulling forces on solder joints and high costs due to limited flexibility and low current carrying capacity.

Innovation Solution

A board-end connector design featuring an insulating housing with a locknut and sliding cover, incorporating an annular boss and limiting structures for axial movement, a conductive sleeve with an elastic coupling member, and a terminal socket with guiding and limiting structures to ensure secure and flexible connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If serpentine springs or soft copper bars are used for flexible connection, then adaptability to spacing variations is improved, but reliability of solder joints deteriorates due to pulling force transmission

Engineering Contradiction:

Improveadaptability to spacing variationsVSAvoidreliability of solder joints

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The flexible connection structure is segmented into multiple independent elastic fingers instead of a single continuous spring or copper bar. Each finger can independently deform to accommodate spacing variations, while the segmentation isolates the elastic deformation from the solder joint, preventing pulling force transmission to the PCB connection point.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection structure transitions from a static rigid or semi-rigid spring to a dynamic elastic finger system that can adapt its shape and position. The elastic fingers can dynamically deform in response to spacing variations between the mounting panel and PCB, absorbing mechanical stress without transmitting it to the solder joints.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If serpentine springs or soft copper bars are used for flexible connection, then adaptability to spacing variations is improved, but manufacturing cost increases

Engineering Contradiction:

Improveadaptability to spacing variationsVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent uses thin elastic fingers made from flexible conductive material instead of bulky serpentine springs or soft copper bars. This thin-film approach reduces material consumption and simplifies manufacturing processes while maintaining the necessary flexibility and electrical conductivity for the connection.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The elastic fingers are designed as simple, easily replaceable components with straightforward geometry. Their simplified structure allows for cost-effective manufacturing through standard PCB fabrication or simple stamping processes, making them more economical than complex spring assemblies while maintaining functional performance.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Adaptability or versatility

If serpentine springs or soft copper bars are used for flexible connection, then adaptability to spacing variations is improved, but current carrying capacity decreases

Engineering Contradiction:

Improveadaptability to spacing variationsVSAvoidcurrent carrying capacity

Core Design Contradiction:

Adaptability or versatilityVSPower

Solution Approach 1:

The elastic fingers are designed with non-uniform cross-sectional properties along their length. The fingers have wider or thicker sections at critical current transmission points to maintain high current carrying capacity, while having narrower or more flexible sections at the mounting points to provide the necessary adaptability to spacing variations. This local quality variation allows simultaneous optimization of both electrical performance and mechanical flexibility.

Inventive Principle:

Principle #3Local quality

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 design allows for axial flexibility, accommodating different spacings and reducing pulling forces on PCB solder joints, while maintaining a secure electrical connection and increased tolerance, thus improving assembly convenience and current carrying capacity.

Implementation Method 1

a conductive sleeve (4) to be mounted in the insulating housing (3), wherein one end of the conductive sleeve (4) is to be used for mated connection with an insertion body (82) of the first terminal (8)

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS20240235077A1Board end connector for flexible connection with PCB

Publication Date: 2024.07.11 PHOENIX ASIAN PACIFIC ELECTRIC NANJING

AI summary

The present disclosure provides a board-end connector for flexible connection with a PCB. According to the present disclosure, a board-end connector is provided. The board-end connector comprises: an insulating housing with openings at both ends; a locknut, to be used for mated installation with a first end of the insulating housing; and a cover, to be used for mated installation with a second end of the insulating housing by insertion, wherein the cover is configured to receive a first terminal having a soldering tail end and, the cover and the second end of the insulating housing, after the mated installation, are capable of sliding axially and being limited within a predetermined spatial range.