Method of making an electrical connection system

• US 8,875,389 B2
• Filed: 11/04/2011
• Issued: 11/04/2014
• Est. Priority Date: 04/12/2010
• Status: Active Grant

• Current Assignee: Flextronics America LLC (Flextronics International Limited)
• Original Assignee: Flextronics America LLC (Flextronics International Limited)
• Inventors: Kan, Ken, Chen, Jeff, Chang, Michael
• Primary Examiner(s): ARBES, CARL J
• Application Number:
  US13/289,927
• Publication Number:
  US 20120047732A1
• Time in Patent Office: 1,096 Days
• Field of Search: 298/25, 298/29, 298/30, 298/32, 298/40
• US Class Current: 29/832
• CPC Class Codes: H01R 13/501 comprising an integral hinge or a frangible part
• CPC Class Codes: H01R 2201/06 for computer periphery
• CPC Class Codes: H01R 31/06 Intermediate parts for linking two coupling parts, e.g. adapter with a holder adapted for supporting apparatus to which its counterpart is attached H01R33/94
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49124 On flat or curved insulated base, e.g., printed circuit, etc.
• CPC Class Codes: Y10T 29/49126 Assembling bases
• CPC Class Codes: Y10T 29/4913 Assembling to base an electrical component, e.g., capacitor, etc.
• CPC Class Codes: Y10T 29/49144 by metal fusion
• CPC Class Codes: Y10T 29/49208 by assembling plural parts
• CPC Class Codes: Y10T 29/4921 with bonding

Abstract

Systems and methods electrically connect a first electronic device or electrical component, having a external electrical connector, to a circuit board of a second electronic device. A low-cost, user-installable connection system isolates mechanical stresses imposed on the external electrical connector to within the user-installable connection system, thereby preventing the mechanical stresses from reaching the circuit board in the second electronic device. If the connection becomes faulty, only the low-cost, user-installable connection system must be replaced.

Claims

1. A method of making an electrical connection system comprising:

a. mechanically coupling an external electrical connector to a mounting element;

b. electrically coupling an internal electrical connector to the external electrical connector, wherein the internal electrical connector is configured for electrically coupling to the first circuit board; and

c. providing a sacrificial portion configured to fail in a predetermined failure mode when a predetermined minimum failure mode force is applied to the external electrical connector.

2. The method of claim 1 wherein providing the sacrificial portion comprises providing a sacrificial portion configured to mechanically fail.

3. The method of claim 2, wherein mechanically coupling the external electrical connector to the mounting element comprises soldering, gluing, epoxying, brazing, welding, encasing, integrally forming, press-fitting, snap-fitting, fastening with threaded fasteners, or any combination thereof.

4. The method of claim 1, wherein providing the sacrificial portion comprises providing a substantially planar mounting element.

5. The method of claim 4, wherein providing the sacrificial portion comprises providing a substantially planar mounting element with a weakened portion.

6. The method of claim 5, wherein providing the substantially planar mounting element with a weakened portion comprises thinning, perforating, scoring, drilling, increasing the brittleness of the substantially planar mounting element, or any combination thereof.

7. The method of claim 1 further comprising electrically coupling the external electrical connector to the mounting element.

8. The method of claim 7 wherein providing the sacrificial portion comprises providing a sacrificial portion configured to electrically fail.

9. The method of claim 8 wherein providing the sacrificial portion configured to electrically fail comprises providing a sacrificial portion configured for the electrical coupling of the external electrical connection to the internal electrical connection to fail.

10. A method of making a user-replaceable electrical connection system comprising:

a. coupling an external electrical connector to a mounting element, such that the coupling is configured to fail in a predetermined failure mode in the presence of a predetermined failure mode force applied to the external electrical connector; and

b. electrically coupling an internal electrical connector to the external electrical connector.

11. The method of claim 10, wherein coupling the external connector to the mounting element comprises mechanically coupling the external connector to the mounting element.

12. The method of claim 11, wherein the coupling is configured to fail mechanically in a predetermined failure mode in the presence of the predetermined failure mode force applied to the external electrical connector.

13. The method of claim 10, further comprising mechanically coupling the internal connector to the mounting element.

14. The method of claim 10, wherein the electrical coupling comprises coupling the internal and external connector with a flexible electrical conduit.

15. The method of claim 13, wherein the mounting element comprises a circuit board and the electrical coupling comprises mounting the external and internal connectors to the circuit board.

16. The method of claim 10, further comprising coupling the mounting element to a housing configured to receive the mounting element.

17. The method of claim 16, wherein the housing is configured for installation into an electronic device.

18. A method of making an electrical connection system, the electrical connection system comprising a mounting element having a substantially planar portion, the mounting element configured for coupling to an external electrical connector and an internal electrical connector, the mounting element configured to fail in a predetermined failure mode in the presence of a predetermined failure mode force applied to the external connector when the external connector is coupled to the mounting element, the method comprising:

providing the mounting element, the substantially planar surface comprising a weakened portion configured to fail in the presence of the predetermined failure mode force applied to the external connector.

19. The method of claim 18, further comprising coupling the external connector to the mounting element.

20. The method of claim 19, further comprising electrically coupling the internal electrical connector to the external electrical connector.