Solderless SPE Wire-to-Board Connector With Press-Fit and IDC Contacts
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Solution Overview
Problem
Traditional soldering methods for connecting wires to printed circuit boards are tedious, inefficient, and result in high scrap rates, making repairs and replacements difficult, especially in applications where components are not easily accessible.
Innovation Solution
A solderless single pair Ethernet (SPE) connector system featuring a female and male connector portion with press-fit pins and insulation displacement contacts (IDCs) that allow for secure, reliable, and efficient connections without soldering, enabling easy disconnection and reconnection of wires to PCBs, while providing electromagnetic interference shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional soldering methods are used to connect wires to PCBs, then reliable electrical connections are achieved, but the process becomes tedious, inefficient, and results in high scrap rates
Solution Approach 1:
The patent replaces the thermal soldering process with a mechanical press-fit system. The connector uses a press-fit pin that mechanically engages with a corresponding receptacle on the PCB, eliminating the need for soldering while maintaining reliable electrical connection. This mechanical substitution resolves the contradiction by providing both reliability and efficiency.
Solution Approach 2:
The invention extracts the soldering step entirely from the connection process. By designing a self-contained press-fit connector that mechanically secures the wire to the PCB without requiring solder, the patent removes the tedious and error-prone soldering operation, thereby improving productivity while maintaining connection reliability.
2Strength
If soldering is used to form permanent connections, then strong electrical bonds are created, but repairs and replacements become difficult especially in hard-to-reach locations
Solution Approach 1:
The patent segments the connection system into separable components: a connector body, a press-fit pin, and a receptacle. This segmentation allows the wire connection to be easily disconnected and reconnected by simply removing the connector from the PCB receptacle, making repairs straightforward while maintaining strong electrical bonds during operation.
Solution Approach 2:
The connection system transitions from a static permanent solder joint to a dynamic reversible mechanical connection. The press-fit design allows the connector to be inserted and removed multiple times, providing ease of repair and replacement while maintaining strong electrical contact when assembled, thus resolving the contradiction between bond strength and reparability.
3Reliability
If soldering processes are used, then electrical connections are formed, but the process is time-consuming and results in high scrap rates
Solution Approach 1:
The connector is pre-assembled with the wire and insulation displacement contact before approaching the PCB. This preliminary preparation eliminates the need for on-site soldering, allowing the connection to be made quickly by simply pressing the pre-assembled connector into the PCB receptacle, thereby reducing time loss while maintaining connection reliability.
Solution Approach 2:
Replacing the time-consuming thermal soldering process with a quick mechanical press-fit operation dramatically reduces connection time. The press-fit mechanism achieves reliable electrical connection in a single pressing motion, eliminating the multiple steps of soldering, cooling, and inspection, thus resolving the contradiction between reliability and time efficiency.
4Reliability
If replacement components are needed after soldering, then new components must be installed, but the process requires disassembly and re-soldering which is complex and time-consuming
Solution Approach 1:
The connector design segments the wire connection from the PCB mounting, allowing the connector body to be easily removed and replaced without affecting the PCB or requiring complex disassembly. This segmentation simplifies the replacement process to a single removal and insertion action while maintaining reliable electrical connections, resolving the contradiction between reliability and replacement complexity.
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 SPE connector ensures durable, versatile, and reliable electrical connections resistant to thermal and mechanical stress, facilitating easy updates and changes in complex systems like industrial applications, with improved data communication integrity and power transmission.
Implementation Method 1
a first electrical contact comprising a first press-fit pin
Implementation Method 2
press-fit pin...configured to connect to a printed circuit board
Implementation Method 3
a second electrical contact comprising an insulation displacement contact (IDC)...configured to connect to a wire
Implementation Method 4
a first outer shield...a second outer shield
Data Source
AI summary
This disclosure provides a method and apparatus for a single pair Ethernet (SPE) wire-to-board connector. The SPE connector may include a female connector portion and a male connector portion. The female connector portion may include a first electrical contact having a first press-fit pin and a first female portion, a second electrical contact having a second press-fit pin and a second female portion, and a first outer shield, the first outer shield mechanically secured to the first insulative housing. The first and second electrical contacts may be positioned partially within the first insulative housing. The male connector portion includes a third electrical contact comprising a first insulation displacement contact (IDC) portion and a first male portion, a fourth electrical contact comprising a second IDC portion and a second male portion, and a second outer shield, the second outer shield mechanically secured to a second insulative housing.