Solderless I/O Connector with Screw Fastening and Sealing
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Solution Overview
Problem
Miniaturization of communication device connectors and frequent use lead to mechanical stress issues, resulting in connector failure, making repair difficult and costly, and requiring frequent replacement, while also being vulnerable to moisture exposure.
Innovation Solution
An injection molded connector body with sealed terminals and a locking mechanism that uses screws to secure the connector to the circuit board, eliminating the need for soldering and providing a watertight seal, allowing for flexibility under external forces and moisture resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional soldered connectors are used, then good electrical connection is achieved, but mechanical stress from frequent attachment and detachment causes connector failure
Solution Approach 1:
The connector is divided into separate components: a connector body that can be detached from the circuit board, and the circuit board itself. This allows the connector body to be replaced independently without replacing the entire circuit board, resolving the contradiction between durability and repairability by enabling easy replacement of the worn connector component.
Solution Approach 2:
The traditional soldered mechanical connection is replaced with a screw-based mechanical fastening system. The connector body is secured to the circuit board using screws that engage with threaded holes, eliminating the brittle solder joint while maintaining secure mechanical and electrical connection. This allows the connector to withstand mechanical stress from frequent attachment and detachment cycles.
2Volume of moving object
If connector size is reduced for miniaturization, then device portability is improved, but mechanical stress resistance deteriorates
Solution Approach 1:
The connector body is designed as a separate, compact component that can be miniaturized without compromising the overall circuit board structure. This segmentation allows the small connector body to be optimized for size while the mounting mechanism provides the necessary mechanical strength through the screw-fastened connection to the circuit board.
Solution Approach 2:
The connector body utilizes a composite construction combining conductive materials for electrical contacts with structural materials for mechanical strength. This allows the miniaturized connector to maintain adequate mechanical stress resistance despite its reduced size, as the composite structure optimizes both electrical and mechanical properties within the compact form factor.
3Ease of operation
If connector is exposed for cable connection, then ease of operation is improved, but vulnerability to moisture increases
Solution Approach 1:
The connector body is pre-sealed with a gasket or sealing structure before cable connection. This preliminary sealing action protects the internal electrical contacts and circuit board connection points from moisture ingress while still allowing external cable access, thus maintaining ease of operation while preventing harmful moisture exposure.
Solution Approach 2:
A flexible sealing gasket or thin film barrier is incorporated around the connector body where it interfaces with the circuit board. This flexible seal maintains the protective barrier against moisture while accommodating the connector's position and allowing external cable access, thus protecting against harmful factors without compromising operational accessibility.
Data Source
AI summary
A sealed, solderless I/O connector for allowing the connection of cables or desk accessories to a mobile communication device while providing a weather tight seal allowing the use of the mobile communication device outdoors. The sealed, solderless I/O connector provides for greater tolerance of mechanical stress due to vibration or dropping because the contact points between the connector and the printed circuit board accomplished with a “U” shaped spring contact. The sealed, solderless I/O connector also provides a locking mechanism to prevent unintended detachment of the cable or desk accessory.