Spring-Loaded Connector for Fan Tray PCB Alignment and Grounding
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Solution Overview
Problem
The existing connection methods between printed circuit boards (PCBs) and fan units in computer systems face challenges such as heat damage, reduced efficiency, and poor electrical connections, which can lead to failures and safety issues due to misalignment and weight distribution on connectors.
Innovation Solution
A system and method that utilize a floating, aligning, centering, and grounding interface with vertical and horizontal springs to connect a fan unit's circuit board to a chassis, allowing for resilient and secure coupling while maintaining electrical continuity, reducing the risk of connector damage and improving airflow for heat removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid connector connection is used between the fan unit and backplane, then electrical connection is established, but the connector is susceptible to damage from misalignment and weight loads
Solution Approach 1:
The connector is designed with spring elements that enable dynamic movement and flexibility. The spring-loaded contact points can deflect to accommodate misalignment while maintaining electrical contact, transforming a static rigid connection into a dynamic adaptive connection that absorbs mechanical stresses.
Solution Approach 2:
Spring elements are incorporated into the connector design to provide pre-compression and cushioning force. This beforehand cushioning protects the connector from damage by absorbing impact forces and misalignment stresses before they can cause damage to the rigid components.
2Manufacturing precision
If precise alignment features are added to ensure connector alignment, then connection accuracy improves, but device complexity and manufacturing cost increase
Solution Approach 1:
The connector design incorporates spring elements with specific mechanical properties (force constants, deflection ranges) that automatically compensate for alignment variations. By changing the mechanical parameters of the spring system, the connector can tolerate a range of misalignments without requiring precision alignment features.
Solution Approach 2:
The spring-loaded connector design allows the connection mechanism to self-align and self-adjust during insertion. The elastic deformation of the spring elements automatically compensates for misalignment, eliminating the need for complex external alignment features or adjustment mechanisms.
3Stability of the object's composition
If the connector is designed to support the full weight of the fan unit, then structural stability is achieved, but the connector and PCB traces are subjected to excessive stress
Solution Approach 1:
The support function is segmented between the spring elements and the PCB mounting structure. The spring elements bear the dynamic insertion forces and provide resilience, while the PCB mounting holes and standoffs handle the static weight support, distributing the mechanical loads across different components.
Solution Approach 2:
The spring elements act as intermediary components between the fan unit weight and the PCB connector. They provide a compliant interface that absorbs mechanical stresses through elastic deformation, protecting the fragile PCB traces from direct stress while maintaining electrical connection.
4Reliability
If grounding features are integrated into the connector, then electrical grounding is achieved, but the connector design becomes more complex
Solution Approach 1:
The grounding function is merged with the power delivery function by using the same spring-loaded contact points for both purposes. The metallic housing and spring elements that provide mechanical resilience also serve as the grounding path, eliminating the need for separate grounding features.
Solution Approach 2:
The connector components, particularly the spring elements and metallic housing, are designed to perform multiple functions simultaneously: providing mechanical resilience, maintaining electrical contact, and establishing grounding paths. This multi-functionality reduces overall connector complexity while achieving reliable grounding.
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
This solution enhances the reliability and safety of connections by providing a resilient and grounded interface that reduces the risk of connector failure, improves airflow for heat management, and prevents damage from misalignment and weight distribution, leading to improved system performance and reduced risk of fire.
Implementation Method 1
a vertical spring coupled with the interface to provide vertical resilience to the second connector
Implementation Method 2
a horizontal spring coupled with the interface to provide horizontal resilience to the second connector
Data Source
AI summary
Systems and methods for connecting a circuit board, such as a circuit board of a fan tray, with a chassis are described herein. Systems and methods for floating, aligning, centering, grounding and blind-mating a connector set are also described herein.