Actuator Direct Plug-in Connection Eliminates Solder

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Solution Overview

Problem

Vehicle air-conditioning unit actuators face issues due to the size and weight of connector sockets and the use of solder, which is a regulated material prone to failure under vibration and incorrect soldering conditions.

Innovation Solution

A direct plug-in connection between the PCB and lead wires eliminates the need for soldered connections, using contact pads and terminals for mechanical and electrical contact, with a connector that grips the PCB to prevent disconnection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a connector socket with soldered pins is used to connect lead wires to the PCB, then reliable electrical connection is achieved, but the size and weight of the actuator increase significantly

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidactuator weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent removes the connector socket and soldered pins from the actuator assembly, extracting only the essential electrical connection function. The lead wires are connected directly to the PCB contact pads without intermediate connector components, eliminating unnecessary weight while maintaining electrical connectivity.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent merges the connector socket function with the PCB itself by integrating contact pads directly onto the PCB. The housing opening that previously accommodated the connector socket is eliminated, and the electrical connection is achieved through direct contact between lead wires and PCB contact pads, combining multiple functions into a single integrated structure.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If a connector socket with soldered pins is used to connect lead wires to the PCB, then reliable electrical connection is achieved, but the device complexity increases due to precise housing openings and mounting requirements

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidhousing structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts and removes the connector socket assembly from the housing structure, eliminating the need for precise housing openings and mounting features. The housing is simplified to only require openings for lead wire access, removing complex structural requirements while maintaining connection reliability through direct PCB contact pads.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of mounting the connector socket to the housing and then connecting lead wires to it, the patent inverts the approach by connecting lead wires directly to the PCB contact pads. This reverses the traditional connection sequence and eliminates the intermediate housing-mounted connector, simplifying the overall device structure.

Inventive Principle:

Principle #13The other way round (Inversion)

3Reliability

If solder is used to connect pins to the PCB and lead wires to the socket, then electrical connection is achieved, but manufacturing issues arise due to regulated material status and failure modes from incorrect soldering

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing process reliability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the soldering process with a mechanical connection system. Lead wires with crimped ferrules make direct mechanical contact with PCB contact pads, eliminating the need for solder. This substitution removes manufacturing complexities associated with soldering while maintaining reliable electrical connection through precise mechanical contact and retention features.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of operation

If a connector socket is mounted in the housing to support supply leads, then connection and disconnection of leads is enabled, but the size of the actuator increases due to the significant size of the connector socket

Engineering Contradiction:

Improvelead wire connection easeVSAvoidactuator volume

Core Design Contradiction:

Ease of operationVSVolume of moving object

Solution Approach 1:

The patent extracts and removes the bulky connector socket from the actuator assembly. Lead wire connection and disconnection are achieved through direct access to PCB contact pads via housing openings, eliminating the need for a large connector socket while maintaining operational ease for lead wire management.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs a flexible retention mechanism using spring-loaded contact pads on the PCB that can accommodate lead wire insertion and removal. This flexible contact system replaces the rigid, space-consuming connector socket, enabling easy lead wire connection while minimizing actuator volume.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS10424986B2Actuator

Publication Date: 2019.09.24 JOHNSON ELECTRIC INTERNATIONAL AG

AI summary

An actuator for a vehicle air-conditioning unit, has a housing, an output driven by a gear train, a motor driving the output via the gear train, a PCB connected to the motor for supplying power to the motor; and lead wires connected to the PCB via a direct connection connector to supply power to the PCB. Terminals of the connector are crimped to the lead wires and make direct mechanical contact with contact pads formed on the PCB.