Angled PCB Connector Assembly for High-Current Circuit Breakers
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Solution Overview
Problem
Existing connector assemblies require significant effort to install and electrically connect circuit breakers, particularly for high-current applications, making them cumbersome and inefficient.
Innovation Solution
A connector assembly with angled pin contacts featuring a plug-in region with intersecting slots and symmetrical segments that allow for easy plugging into through-contact openings of a printed circuit board, providing elasticity and a large contact area for high-current transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional connector assemblies are used to connect circuit breakers to printed circuit boards, then electrical connection is achieved, but the installation effort and complexity increase significantly
Solution Approach 1:
The pin contact is segmented into multiple plug-in segments (at least two) separated by slots, allowing the connector to be divided into flexible sections that can adapt to the through-contact opening during insertion, simplifying the installation process while maintaining structural integrity
Solution Approach 2:
The plug-in region is designed with elastic properties, allowing it to deform dynamically during insertion and then return to its original shape, enabling easy plug-in operation without complex fastening mechanisms
2Reliability
If the plug-in region is designed with large contact area for high-current transmission, then current-carrying capacity increases, but manufacturing complexity increases
Solution Approach 1:
The plug-in region is divided into multiple segments by slots, where each segment contributes to the overall contact area. This segmentation allows the large contact area to be achieved through simple geometric repetition rather than complex monolithic structures, easing manufacturing
Solution Approach 2:
The pin contact geometry is optimized with specific parameters including the connection angle (30°-60°) and slot dimensions, allowing the contact area to be adjusted by changing geometric parameters rather than redesigning the entire structure, simplifying manufacturing while maintaining high current-carrying capacity
3Reliability
If pin contacts are designed with angled configuration for circuit breaker connection, then electrical connection to terminals is improved, but manufacturing precision requirements increase
Solution Approach 1:
The pin contact features an asymmetric angled configuration where the connection portion is inclined at a specific angle (30°-60°) relative to the plug-in axis. This asymmetric design optimizes the electrical connection to circuit breaker terminals while the angle range provides manufacturing tolerance, reducing precision requirements
Solution Approach 2:
The angled pin contact is divided into distinct functional regions (terminal region, connection portion, plug-in region) separated by slots, allowing each region to be manufactured and assembled independently, reducing the cumulative precision requirements compared to a monolithic angled structure
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
Enables easy and secure fastening and electrical connection of circuit breakers to printed circuit boards with high current-carrying capacity, minimizing manual effort and optimizing contact surface area for efficient current transfer.
Implementation Method 1
at least two slots crossing each other in the plug-in axis, whereby at least four plug-in segments, each with a circular-segment-like outer contour, are formed in the plug-in region of the respective pin contact
Implementation Method 2
a terminal-side terminal region for electrically conductive connection to the circuit breaker, a plug-in-side plug-in region for plugging into a through-contact opening of a printed circuit board
Data Source
AI summary
The aim of the disclosure is to electrically connect and secure a circuit breaker to a printed circuit board in a simple and comfortable manner. For this purpose, a connector assembly is proposed having two angled pin contacts, each of which has a plug region with at least four plug segments facing the plug-in direction.