Twisted Interconnect Pin for Misaligned Vias in Remote Control

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Solution Overview

Problem

Portable remote control devices like key fobs face packaging constraints, requiring components to fit within a small space, which complicates the alignment and connection of electrical and battery components, especially when vias on the motherboard and battery daughterboard are misaligned.

Innovation Solution

The use of a custom interconnect with a twisted pin configuration that aligns with misaligned vias on the motherboard and battery daughterboard, allowing for mechanical and electrical connection while maintaining a compact design, and a battery daughterboard with a battery holder to secure the battery, enabling efficient energy supply to the electrical circuit elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If a compact design is used to meet packaging constraints, then the device size is reduced, but the alignment of vias on motherboard and battery daughterboard becomes difficult

Engineering Contradiction:

Improvedevice sizeVSAvoidvia alignment

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The interconnect is segmented into multiple functional portions: a first portion that interfaces with the battery daughterboard, a second portion that interfaces with the motherboard, and an intermediate portion that bridges between them. This segmentation allows each portion to be optimized independently for its specific interface requirements, enabling via alignment compensation while maintaining compact overall dimensions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The intermediate portion of the interconnect introduces a dimensional transformation by extending in multiple directions (x, y, and z axes) rather than a simple linear connection. This multi-dimensional configuration allows the interconnect to bridge misaligned vias by navigating through three-dimensional space, effectively compensating for manufacturing tolerances and alignment variations in a compact footprint.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Volume of moving object

If misaligned vias are used to accommodate compact layout, then packaging constraints are satisfied, but electrical connection reliability deteriorates

Engineering Contradiction:

Improvedevice sizeVSAvoidelectrical connection

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The intermediate portion of the interconnect acts as an intermediary element that bridges the misaligned vias between the battery daughterboard and motherboard. This intermediary structure provides a reliable electrical connection path that compensates for the misalignment, ensuring signal integrity and electrical reliability while enabling the compact via layout.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If a twisted pin configuration is used to connect misaligned vias, then via alignment flexibility is improved, but interconnect complexity increases

Engineering Contradiction:

Improvevia alignment flexibilityVSAvoidinterconnect complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Multiple functional requirements are merged into a single intermediate portion of the interconnect: mechanical support, electrical connection, via alignment compensation, and structural stability. By combining these functions into one integrated element rather than using separate components, the design achieves via alignment flexibility without proportionally increasing overall interconnect complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The twisted configuration of the intermediate portion employs curved and angled geometries rather than straight linear connections. This curved path allows the interconnect to navigate the three-dimensional space between misaligned vias, providing alignment flexibility while maintaining a compact form factor and manageable structural complexity.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Ease of manufacture

If battery daughterboard is separated from motherboard, then manufacturing and assembly are simplified, but mechanical stability deteriorates

Engineering Contradiction:

Improvemanufacturing and assemblyVSAvoidmechanical stability

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The system is segmented into separate battery daughterboard and motherboard components that can be manufactured and tested independently, improving ease of manufacture. The interconnect provides the mechanical linkage that restores stability when the components are assembled together, achieving both manufacturing simplicity and structural stability through modular design.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS9930780B1Remote control device having motherboard and battery daughterboard connected by interconnect

Publication Date: 2018.03.27 LEAR CORP

AI summary

A portable remote control device such as a key fob includes a motherboard, a battery daughterboard having a battery holder to secure a battery, and an interconnect mounting the battery daughterboard to the motherboard. The battery daughterboard may include a first via and the motherboard may include a second via in which the vias are misaligned with one another. The interconnect includes a first pin inserted through the first via and the second via to mount the battery daughterboard to the motherboard. The first pin has a disjointed configuration over a length of the pin in correspondence with a misalignment of the first via and the second via.