Adapter for Mounting Overvoltage Protection Devices
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Solution Overview
Problem
Existing methods for connecting overvoltage protection devices to wiring supports, such as printed circuit boards, require soldering, which is costly and thermally stressful, and result in high contact resistance and low surge current capacity.
Innovation Solution
An adapter with a base and chamber that uses complementary mounting extensions and metallized recesses for a solder-free, self-locking connection that withstands surge currents, featuring hook-shaped mounting tabs and U-shaped plug-in connections for secure electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect overvoltage protection devices to wiring supports, then reliable electrical connection is achieved, but thermal stress increases and manufacturing cost rises
Solution Approach 1:
The patent replaces the thermal soldering process with a mechanical press-fit connection system. The adapter uses mounting projections that engage with recesses in the wiring support through purely mechanical force, eliminating the need for soldering heat and associated thermal stress while maintaining reliable electrical connection through the metallized contact surfaces.
Solution Approach 2:
The adapter serves as an intermediary component between the overvoltage protection device and the wiring support. It provides the mechanical press-fit connection interface while maintaining electrical contact through metallized surfaces, thus mediating between the device needing connection and the wiring support without requiring direct soldering.
2Reliability
If soldering is used to connect overvoltage protection devices, then stable electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces the costly soldering process with a mechanical press-fit system using the adapter. This eliminates soldering materials, soldering equipment requirements, and associated labor costs, while maintaining stable electrical connection through the metallized contact surfaces and precise mechanical engagement.
Solution Approach 2:
The adapter's mounting projections are designed to automatically engage with the recesses in the wiring support through elastic deformation and geometric interlocking. This self-locking mechanism eliminates the need for additional fastening operations or complex assembly procedures, reducing manufacturing cost while ensuring stable connection.
3Ease of manufacture
If solder-free connection is used, then manufacturing cost decreases and thermal stress is reduced, but surge current capacity is insufficient
Solution Approach 1:
The patent segments the connection function into two distinct parts: the adapter provides the mechanical press-fit structure for solder-free assembly, while the metallized surfaces on the mounting projections and in the recesses provide the low-resistance electrical contact path for surge currents. This segmentation allows each component to optimize its specific function.
Solution Approach 2:
The adapter incorporates metallized surfaces (metal coating) on its mounting projections, creating a composite structure that combines the mechanical properties of the base material with the high electrical conductivity of the metal coating. This composite approach enables the plastic adapter body to provide mechanical retention while the metallized surfaces handle high surge current loads.
4Ease of operation
If mechanical press-fit connection is used without metallized surfaces, then assembly is simplified, but contact resistance increases
Solution Approach 1:
The patent applies metallized surfaces locally only at the critical contact points where electrical connection is needed (the mounting projections and corresponding recesses). This localized metallization maintains the overall simplicity of the press-fit assembly process while ensuring low contact resistance at the specific interfaces where electrical current flows.
Data Source
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AI summary
The invention relates to an adapter for mounting single- or multi-pin overvoltage protection devices that are designed as plug-in modules on a wiring carrier, wherein the adapter has a base and at least one chamber that is open upward and bounded by side walls, from the bottom side of which chamber a plurality of mounting protrusions extend, which each have a contour that is substantially complementary to corresponding openings in the wiring carrier. According to the invention, the mounting protrusions have a hook shape in order to engage under the wiring carrier as a result of sliding of the adapter in the plane of the wiring carrier, after the adapter has been inserted into the openings by means of the mounting protrusions, wherein through-holes are formed in the base, the dimensions of which through-holes allow plug-in connections of the plug-in modules to be fed through to the wiring carrier. Furthermore, metallized holes corresponding to the dimensions of the plug-in connections of the plug-in module are formed in the wiring carrier in such a way that the holes are located congruently with the through-holes in the base after the adapter has been inserted and slid, such that self-securing locking of the combination of the adapter, the plug-in module, and the wiring carrier is provided in addition to electrical contacting, after the plug-in module has been inserted.