Spring Finger Connector PCB Cavity Design
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Solution Overview
Problem
Standard off-the-shelf connectors are expensive and inflexible, while custom connectors have high setup fees, long lead times, and limited design flexibility, making them unsuitable for cost-effective and rapid design iterations.
Innovation Solution
A two-part connector system comprising a plug with spring finger contacts and a receptacle, where the receptacle features a pre-impregnation layer sandwiched between two layers to form a cavity for the connector, allowing for quick design modifications and low-cost production using standard PCB manufacturing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard off-the-shelf connectors are used, then cost per pin is reduced, but design flexibility and adaptability are restricted
Solution Approach 1:
The connector system is divided into modular components: a receptacle module with cavity and contacts, and a plug module with spring fingers. These modules can be independently designed and manufactured using standard PCB techniques, then assembled together. This segmentation allows the use of cost-effective standard manufacturing processes while maintaining design flexibility through modular reconfiguration.
Solution Approach 2:
The receptacle cavity design with multiple layers and the spring finger contact system create a universal connector platform that can accommodate various contact arrangements and configurations. The same basic receptacle structure can support different numbers and types of contacts, allowing a single design framework to serve multiple application requirements.
2Adaptability or versatility
If custom connectors are designed, then design flexibility is improved, but setup fees and lead time increase substantially
Solution Approach 1:
The receptacle is pre-formed with a cavity structure during PCB manufacturing, and contacts are pre-positioned on the PCB layers before final assembly. The spring fingers are pre-assembled on the plug substrate. These preliminary actions during manufacturing reduce final assembly complexity and lead time, while maintaining custom design flexibility.
Solution Approach 2:
The invention uses standard PCB manufacturing processes to create connector components, effectively copying proven, low-cost manufacturing techniques from the PCB industry. This allows custom connector designs to be produced using established, rapid PCB fabrication processes rather than requiring new tooling and manufacturing setups.
3Adaptability or versatility
If custom connectors are designed, then design flexibility is improved, but setup fees increase due to mold and back shell design
Solution Approach 1:
The invention replaces traditional mechanical connector components (molds, back shells, separate contact holders) with PCB-based structures. The receptacle cavity is formed directly in the PCB layers, contacts are mounted on the PCB, and the plug uses a PCB substrate with spring fingers. This substitution eliminates the need for expensive custom tooling and mechanical assemblies, achieving custom design flexibility through standard PCB manufacturing.
Solution Approach 2:
The connector system combines PCB materials (frictionless board, copper traces, solder mask) with metal spring fingers and conductive materials. This composite approach leverages the cost-effectiveness and design flexibility of PCB technology while maintaining the electrical and mechanical performance required for connector applications.
4Adaptability or versatility
If custom connectors are designed, then specific application requirements are met, but manufacturing complexity increases
Solution Approach 1:
The connector is segmented into independent PCB-based modules (receptacle, plug, contacts) that can be manufactured using standard PCB processes. This segmentation reduces manufacturing complexity by applying well-established PCB fabrication techniques rather than requiring complex custom tooling and assembly processes for the entire connector system.
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 system offers a low-cost, flexible connector solution with reduced design and fabrication cycles, enabling rapid modifications and cost-effective production compared to custom connectors, while maintaining design flexibility.
Implementation Method 1
bonding the first and a second layer to the pre-impregnation layer
Data Source
AI summary
A spring finger interconnection system can include a plug and a receptacle. In one embodiment, the plug can include spring finger contacts configured to carry electrical signals. The receptacle can include a cavity to receive the plug and the cavity can be constructed with printed circuit board fabrication techniques. In one embodiment, the cavity can be formed, at least in part, in a pre-impregnation layer and a first and a second layer can be disposed above and below the pre-impregnation layer to further form the cavity. In one embodiment, contacts can be arranged on the first layer to contact the spring fingers when the plug is inserted into the cavity. In another embodiment, contacts can be arranged on both the first and the second layers. In yet another embodiment, the cavity can be shaped to aid in contact-to-spring finger alignment when the plug is inserted in the cavity.