Under-mounted Leaf Spring Connector for Compact PCB Design
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Solution Overview
Problem
The challenge in electronic device manufacturing is the difficulty in positioning connectors due to space constraints, often requiring more expensive or less available connectors or increasing the device size, as standard connectors may not fit in compact locations with insufficient clearance.
Innovation Solution
The implementation of an under-mounted leaf spring connector assembly, where the connector is mounted to the underside of a printed circuit board, reducing its effective working height and allowing it to fit in spaces with limited clearance by extending through a notch or opening, enabling electrical connections to external components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard connectors are used in compact locations, then electrical connections can be established, but the device size must be increased to accommodate the connector clearance requirements
Solution Approach 1:
The connector is repositioned from a traditional side-mounted configuration to an under-mounted configuration on the PCB. This dimensional change allows the connector to utilize the vertical space beneath the PCB, effectively reducing the horizontal clearance requirements and enabling compact device design while maintaining reliable electrical connections.
Solution Approach 2:
Instead of mounting the connector on the conventional side of the PCB where it would require significant clearance space, the connector is inverted and mounted on the underside of the PCB. This inversion allows the connector to extend through openings in the PCB from below, eliminating the need for large clearance zones around the connector on the device exterior.
2Reliability
If standard connectors are used in compact locations, then electrical connections can be established, but more expensive or less readily available connectors must be used
Solution Approach 1:
The under-mounted connector design allows standard, readily available connectors to serve the dual function of providing reliable electrical connections while fitting within compact device form factors. This universal approach eliminates the need for specialized expensive connectors, as the same standard connectors can be used across different device sizes and configurations when mounted underneath the PCB.
Solution Approach 2:
The invention uses standard connector designs that are already widely available and well-documented, rather than developing custom expensive connectors. By replicating the use of these standard connectors in an under-mounted configuration, the design achieves compact integration without sacrificing connector availability or increasing manufacturing complexity.
3Volume of moving object
If connector clearance space is reduced, then device size can be maintained, but standard connectors cannot fit and function properly
Solution Approach 1:
The connector is repositioned from a horizontal mounting configuration to a vertical under-mounted configuration. This allows the connector to extend through openings in the PCB from the underside, effectively moving the connector body outside the device's horizontal clearance envelope while maintaining proper electrical connection functionality.
Solution Approach 2:
The connector assembly is segmented into multiple functional parts: the connector body mounted on the underside of the PCB, the contact elements extending through openings in the PCB, and the electrical connection points on the circuit board. This segmentation allows each part to be optimized for its specific function while fitting within compact space constraints.
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 allows the use of standard connectors in space-constrained areas, reducing the need for more expensive alternatives and maintaining the compact size of electronic devices while ensuring reliable electrical connections.
Implementation Method 1
leaf spring connector may be formed from a single piece of conductive material... shaped to include a support contact surface, a mating surface and a curved spring arm
Data Source
AI summary
An apparatus includes a support structure and a leaf spring connector coupled to the support structure. The leaf spring connector has a working height measured from a first surface of the two-sided support structure to a mating surface of the leaf spring connector when the leaf spring connector is in a compressed position. The leaf spring connector is mounted below the first surface of the support structure in order to reduce the working height of the leaf spring connector by at least a portion of a thickness of the support structure.