Low-cost SMT PCB Connector with Segmented Mating Features
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Solution Overview
Problem
Existing methods for interconnecting printed circuit boards (PCBs) using connectors or jumper wires are costly and lack mechanical integrity, with connectors requiring precise alignment and jumper wires being difficult to automate and providing limited mechanical interconnection.
Innovation Solution
A low-cost interconnection system comprising a support platform with a separator and contact pins that are secured to mounting pads on each PCB, ensuring precise alignment and mechanical stability without the need for connectors or jumper wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connectors are used to interconnect PCBs, then electrical and mechanical connection is achieved, but cost and device complexity increase
Solution Approach 1:
The connector is divided into two separate components: a first connector component mounted on the first PCB and a second connector component mounted on the second PCB. Each component contains mating features that engage with each other when the PCBs are connected, eliminating the need for a single complex connector structure and reducing overall device complexity while maintaining mechanical integrity.
Solution Approach 2:
The contact pins are embedded within the connector components, which are themselves mounted on the PCBs. The mating features are nested within each other when connected, creating a compact integrated structure that reduces the overall size and complexity of the interconnection system.
2Reliability
If connectors are used to interconnect PCBs, then electrical and mechanical connection is achieved, but manufacturing cost increases
Solution Approach 1:
By segmenting the connector into two separate components that can be independently manufactured and mounted on each PCB, the manufacturing process becomes simpler and more cost-effective. Each connector component can be produced using standard SMT processes without requiring complex alignment fixtures or specialized assembly equipment.
Solution Approach 2:
The connector components are designed to perform multiple functions: providing electrical connection through contact pins, mechanical support through the connector body, and alignment guidance through the mating features. This multi-functionality eliminates the need for separate components for each function, reducing overall cost.
3Reliability
If connectors are used to interconnect PCBs, then electrical and mechanical connection is achieved, but alignment precision requirements increase
Solution Approach 1:
The mating features are designed with asymmetric geometries that provide self-alignment capabilities. The features are configured to guide the PCBs into proper alignment as they are brought together, reducing the precision requirements for manual or automated mounting processes while ensuring reliable electrical and mechanical connections.
4Ease of manufacture
If jumper wires are used to interconnect PCBs, then cost is reduced, but mechanical interconnection integrity deteriorates
Solution Approach 1:
The connector components merge the functions of electrical connection (contact pins) and mechanical support (connector body with mating features) into single integrated structures mounted on each PCB. This combination provides both electrical connectivity and robust mechanical interconnection, overcoming the limitation of jumper wires that provide only electrical connection.
Data Source
AI summary
An interconnection system includes a first support surface positionable against a respective first surface of a first printed circuit board (PCB) and a second support surface positionable against a respective first surface of a second PCB. The first PCB has a respective second surface spaced apart from the respective first surface by a first thickness. The second PCB has a respective second surface spaced apart from the respective first surface by a second thickness. A separator extends from the first support surface and from the second support surface. A contact pin extends through the separator. A portion of the contact pin extending in first direction from the separator is spaced apart from the first support surface by a distance corresponding to the first thickness. A portion of the contact pin extending in a second direction from the separator is spaced apart from the second support surface by the second thickness.