Zero Insertion Force Connector With Segmented Multi-Row Contacts
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Solution Overview
Problem
Conventional electrical connectors have limited density and complex assembly processes, making them inadequate for testing devices with higher numbers of contact pads or complex pad arrays, and they require extensive robotic assembly.
Innovation Solution
A modular electrical connector design with elongated contacts and a contact block that supports dual-sided mating and multi-row contact capabilities, featuring a lever and contact organizer for easy assembly and disassembly, allowing for zero insertion force and contact wiping mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional electrical connectors are used, then assembly is simplified, but contact density is limited and cannot support higher numbers of contact pads
Solution Approach 1:
The connector is divided into multiple independent contact rows (first row, second row, third row, fourth row) that can be separately assembled and configured. Each row contains multiple contacts that can be independently positioned to match different contact pad arrangements on the PCB, enabling high-density connections without requiring a monolithic complex structure
Solution Approach 2:
The connector utilizes multi-row configuration where contacts are arranged in multiple parallel rows (first row, second row, third row, fourth row) rather than a single linear array. This dimensional expansion allows significantly higher contact density by distributing contacts across multiple spatial dimensions while maintaining modular assembly simplicity
2Manufacturing precision
If conventional electrical connectors with extensive automated assembly are used, then assembly precision is improved, but assembly complexity and cost increase due to extensive robotic assembly tooling
Solution Approach 1:
The connector is segmented into modular rows that can be independently assembled and then combined. This segmentation allows for simpler individual assembly operations that can be performed with less complex tooling, while the final assembled product achieves high precision through the modular integration of pre-assembled units
Solution Approach 2:
Individual contact rows are prepared and pre-assembled as separate modules before final integration into the complete connector assembly. This preliminary preparation of standardized modules enables more straightforward final assembly with reduced complexity, as the challenging positioning work has already been completed during modular fabrication
3Adaptability or versatility
If conventional connectors are used, then manufacturing is simplified, but adaptability to different contact pad arrays is reduced
Solution Approach 1:
The connector is divided into separate contact rows that can be independently configured. Each row can be designed with different contact patterns, spacing, and arrangements to match various PCB contact pad layouts, enabling the same basic connector structure to adapt to multiple different array configurations without requiring complete redesign
Solution Approach 2:
The multi-row contact structure serves multiple functions: it can accommodate different contact pad arrangements across different rows, support various density requirements, and interface with different PCB designs. This universal design allows a single connector type to replace multiple specialized connector designs, enhancing adaptability without proportionally increasing complexity
Data Source
AI summary
A connector for establishing electrical connections with a PCB comprises first and second sets of contact pads arranged in first and second rows on a same surface of the PCB. The connector includes a first set of elongated contacts, a second set of elongated contacts, and a contact block. The first set of contacts have contact surfaces that form a first row of contact surfaces configured to make and break electrical connectivity with the first set of contact pads of the PCB. The second set of contacts have contact surfaces that form a second row of contact surfaces configured to make and break electrical connectivity with the second set of contact pads of the PCB. The contact block supports the first and second sets of contacts and causes the contact surfaces to wipe against the first and second sets of contact pads when making and breaking electrical connectivity therewith.