Wire-to-board connector resilient metal elements
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Solution Overview
Problem
Conventional wire-to-board connectors are laborious to assemble due to the need for precise alignment of conductive pins and holes, leading to potential bending and damage, resulting in increased assembly time and labor inefficiency.
Innovation Solution
A wire-to-board connector design featuring a plug receptacle with signal contacts and a mating header equipped with resilient metal elements that establish electrical communication, allowing for easy alignment and secure connection without the risk of pin bending, using an insert body with parallel channels and bent metal sections for secure contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional conductive pins and through holes are used for electrical connection, then electrical communication can be established, but precise alignment is required which increases assembly difficulty and time
Solution Approach 1:
The patent replaces rigid conductive pins with flexible resilient metal elements that can dynamically adapt to alignment variations during assembly. These elements possess elastic properties allowing them to bend and conform to slight misalignments between the mating header holes and plug receptacle pins, thereby establishing reliable electrical contact without requiring precise manual alignment.
Solution Approach 2:
The patent changes the physical state and properties of the connection elements by using resilient metal elements with specific elastic characteristics instead of rigid pins. The resilient elements can deform within certain parameter ranges to accommodate alignment tolerances, transforming the connection from a rigid precision-dependent interface to a flexible tolerance-friendly interface.
2Reliability
If manual assembly with precise alignment is used, then electrical connection can be established, but assembly time increases and production efficiency decreases
Solution Approach 1:
The resilient metal elements perform self-alignment during the insertion process. As the mating header is inserted into the plug receptacle, the resilient elements automatically conform to the correct position through their elastic deformation, eliminating the need for operators to manually align components. This self-aligning mechanism significantly reduces assembly time and improves productivity while maintaining reliable electrical connection.
3Reliability
If rigid conductive pins are used, then electrical communication is established, but the pins are prone to bending and damage during assembly
Solution Approach 1:
The patent replaces static rigid pins with dynamic resilient metal elements that can elastically deform to absorb assembly stresses. These elements bend flexibly during insertion to accommodate minor misalignments and then return to their original shape, preventing permanent deformation or breakage that would occur with rigid pins subjected to the same forces.
Solution Approach 2:
The resilient metal elements provide built-in cushioning against assembly forces before damage can occur. Their elastic properties allow them to absorb and dissipate impact energies during insertion, protecting the electrical connection structure from damage that would otherwise compromise reliability.
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 design enhances assembly efficiency and manufacturing quality by ensuring accurate and stable connections between the circuit board and transmission wire unit, reducing the risk of damage and improving production efficiency.
Implementation Method 1
a plurality of resilient metal elements electrically connecting the transmission wire unit. When the mating header is inserted into the plug receptacle, the resilient metal elements respectively contact with the signal contacts
Data Source
AI summary
A wire-to-board connector for coupling electrically a circuit board to a transmission wire unit, includes a plug receptacle, a plurality of signal contacts and a mating header. The plug receptacle is mounted on the circuit board. The mating header includes an insert body that is disposed at one end of the transmission wire unit and that has a plurality of resilient metal elements. When the insert body is plugged into the plug receptacle, the resilient metal elements respectively contact with the signal contacts of the plug receptacle, thereby establishing electrical communication with the circuit board and the transmission wire unit.