Variable Depth Plug Grounding for PCB Frame Tolerance Compensation
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Solution Overview
Problem
Existing ground connections between printed circuit boards and electrically conductive frames in electrical devices often result in disturbance currents and fields due to varying frame dimensions and complex production processes, leading to unreliable contact and increased signal interference.
Innovation Solution
A device and method utilizing a plug connection with variable insertion depth for ground connection between the printed circuit board and frame, which includes stabilizing elements and connecting parts to compensate for frame dimension tolerances, ensuring reliable and efficient electrical contact while minimizing disturbance fields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw connections or spring contacts are used for ground connection, then reliable electrical contact can be established, but the production process becomes complex and time-consuming
Solution Approach 1:
The invention extracts the ground connection function from complex mechanical fastening systems (screws, spring contacts) and integrates it directly into the plug connection structure. The plug connection itself serves dual purposes: mechanical attachment and electrical grounding, eliminating the need for separate ground connection components and simplifying the production process.
Solution Approach 2:
The invention merges the mechanical connection function and electrical ground connection function into a single integrated plug connection. The plug connector includes both mechanical engagement features and electrical contact elements, allowing simultaneous achievement of mechanical attachment and electrical grounding in one operation, thereby reducing production complexity.
2Reliability
If spring contacts are used for ground connection, then electrical contact can be established, but valuable space on the printed circuit board is consumed
Solution Approach 1:
The invention combines the mechanical mounting function and electrical grounding function into a single plug connection structure. The plug connector integrates both the mechanical attachment mechanism and the electrical contact elements, eliminating the need for separate spring contacts on the printed circuit board and freeing up valuable board space.
3Reliability
If hard anodized coating is applied to spring contacts, then contact reliability improves, but machining complexity and production cost increase
Solution Approach 1:
The invention removes the complex hard anodized coating process from the ground connection solution. Instead of requiring specialized surface treatment of spring contacts, the plug connection uses standard metallurgical materials that achieve reliable electrical contact without additional machining or coating steps, significantly simplifying manufacturing.
4Adaptability or versatility
If frame dimensions vary within tolerance ranges, then manufacturing flexibility is maintained, but ground connection reliability deteriorates
Solution Approach 1:
The invention introduces dynamic adaptability into the plug connection structure through elastic elements that can deform within a certain range. This allows the connection to automatically adjust to variations in frame dimensions while maintaining reliable electrical contact, accommodating manufacturing tolerances without compromising connection reliability.
Solution Approach 2:
The invention utilizes parameter changes in the elastic elements of the plug connection to compensate for dimensional variations. The elastic properties allow the connection parameters (contact force, position) to change dynamically, ensuring reliable ground connection despite variations in frame dimensions within the specified tolerance ranges.
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 solution effectively reduces disturbance fields by geometrically close grounding of electrical disturbances, allowing for automated batch production and improved signal integrity, while simplifying the production process and reducing manual involvement.
Implementation Method 1
at least two plug connections, in each case having a variable insertion depth, for electrically conductively connecting the at least one ground contact of the printed circuit board to the frame
Data Source
AI summary
The ground connection between the circuit card and the housing and the housing connection side is implemented by at least one plug-in connection of variable insertion depth. This design is particularly advantageous for producing corresponding devices in an automated manner because, owing to the assembly of the devices, the contact-connection of the circuit card to ground also takes place automatically, specifically as desired in the advantageous form of meshed grounding with simultaneous compensation of the housing tolerances which is made possible by the plug-in connection of variable insertion depth.