Stepped Connector Housing for Variable PCB Thickness Contact
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Solution Overview
Problem
Conventional connectors fail to provide stable coupling with main circuit boards of varying thicknesses, leading to potential contact failures.
Innovation Solution
A connector design featuring a housing with a stepped sidewall shape and an adjustable spacing control unit, allowing stable connection regardless of the main circuit board's thickness, with a contact terminal protruding from the second bottom portion towards the first bottom portion and an elastic spacing control unit to ensure secure contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional connector with fixed housing structure is used, then the manufacturing and assembly process is simple, but the connector cannot adapt to main circuit boards of varying thicknesses, leading to contact failures
Solution Approach 1:
The housing is divided into multiple bottom portions (first bottom portion, second bottom portion, third bottom portion) with different depths, creating a stepped structure that can accommodate boards of varying thicknesses. Each bottom portion serves a specific depth range, allowing the connector to adapt to different board thicknesses without requiring a completely different housing design.
Solution Approach 2:
The second bottom portion is designed to be movable relative to the first and third bottom portions, allowing it to adjust its position dynamically. This movement capability enables the connector to adapt to different board thicknesses by positioning the contact terminal at the appropriate depth, transforming a static housing structure into a dynamic one that can respond to varying board thicknesses.
2Reliability
If the distance between bottom portions is fixed, then the housing structure is simple and easy to manufacture, but contact reliability deteriorates when board thickness varies
Solution Approach 1:
The spacing control unit enables the second bottom portion to move dynamically, adjusting the distance between bottom portions based on board thickness. This dynamic adjustment mechanism ensures reliable contact by positioning the contact terminal at the correct depth regardless of board thickness variations, while the spring element provides the necessary mechanical complexity in a simple and effective manner.
Solution Approach 2:
The spring element changes the physical state of the spacing control unit from rigid to elastic, allowing it to deform and adjust the distance between bottom portions. This parameter change (from fixed distance to variable distance) enables the connector to maintain contact reliability across different board thicknesses while adding minimal complexity through the use of a simple spring mechanism.
3Adaptability or versatility
If a stepped sidewall structure with multiple bottom portions is implemented, then adaptability to different board thicknesses is improved, but the housing structure becomes more complex
Solution Approach 1:
The housing is segmented into multiple bottom portions with different depths, creating a stepped structure that naturally adapts to various board thicknesses. This segmentation allows each portion to be optimized for specific thickness ranges while maintaining a relatively simple overall manufacturing process, as the stepped structure can be formed using standard molding or machining techniques.
Solution Approach 2:
The stepped housing structure with multiple bottom portions serves multiple functions: it provides adaptability to different board thicknesses, maintains structural integrity, and guides the insertion of the board. This multi-functional design achieves high compatibility with various board thicknesses without requiring multiple different housing designs, thereby maintaining ease of manufacture through a universal housing structure.
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 connector ensures reliable contact between the main circuit board and the connector, preventing contact failures across different board thicknesses, thereby enhancing connection stability and reliability.
Implementation Method 1
the spacing control unit may include a material having elasticity
Data Source
AI summary
A connector includes a housing having a sidewall portion, a first bottom portion protruding from the sidewall portion, and a second bottom portion protruding from the sidewall portion and facing the first bottom portion and, a contact terminal disposed in an internal space of the housing. The sidewall portion includes a first partial sidewall portion having a first width and a second partial sidewall portion having a second width different from the first width. The sidewall portion, the first bottom portion, and the second bottom portion define the internal space.