Biased Connector Pin Assembly for Stable Aerosol Electrical Contacts

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Solution Overview

Problem

Existing aerosol delivery devices face challenges in achieving reliable electrical connections due to complex assembly processes involving soldering and poor connections at joints, which can lead to inefficiencies and increased assembly time.

Innovation Solution

The aerosol delivery device employs a connector pin with biased first and second heads that apply compressive forces for stable electrical connections, eliminating the need for soldering and reducing assembly complexity by ensuring a secure fit with electrical interfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional soldering and complex assembly processes are used for electrical connections, then connection stability may be improved, but assembly time and device complexity increase

Engineering Contradiction:

Improveelectrical connection stabilityVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent extracts the soldering process from the assembly procedure by using a connector pin with biased heads that create mechanical compression contacts instead of soldered joints. This eliminates the need for soldering equipment and complex assembly steps while maintaining reliable electrical connections through spring-loaded compression contacts.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the thermal-mechanical soldering process with a purely mechanical compression contact system. The biased heads of the connector pin apply continuous compressive force to maintain reliable electrical contact without requiring heat, solder, or complex assembly procedures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If traditional soldering and complex assembly processes are used for electrical connections, then connection stability may be improved, but device complexity increases

Engineering Contradiction:

Improveelectrical connection stabilityVSAvoidassembly process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent removes soldering equipment, solder materials, and complex assembly procedures from the system by implementing a standalone connector pin with integrated biasing mechanism. This simplifies the overall device complexity while maintaining connection reliability through mechanical compression.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The connector pin incorporates an integrated biasing mechanism (spring or elastic element) that automatically maintains compression force on the electrical contacts. This self-regulating feature eliminates the need for external adjustment mechanisms or complex assembly procedures, reducing device complexity while ensuring reliable connections.

Inventive Principle:

Principle #25Self-service

3Productivity

If connector pin with biased heads is used, then assembly time is reduced, but manufacturing precision requirements increase

Engineering Contradiction:

Improveassembly speedVSAvoidconnection alignment precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent employs dynamic biased heads that can elastically deform and adapt to slight misalignments in the connection interface. The spring-loaded mechanism provides tolerance compensation, allowing for faster assembly without requiring extremely tight manufacturing tolerances, thus maintaining productivity while reducing precision requirements.

Inventive Principle:

Principle #15Dynamics

4Loss of substance

If connector pin with biased heads is used, then material usage is reduced, but connection force requirements increase

Engineering Contradiction:

Improvematerial usageVSAvoidcompressive force on contacts

Core Design Contradiction:

Loss of substanceVSForce

Solution Approach 1:

The patent changes the force parameter from a static connection (soldering) to a dynamic compression force applied by biased heads. The spring constant and pre-compression force are optimized to provide sufficient contact pressure for reliable electrical connection while using minimal material, achieving both material reduction and adequate connection force.

Inventive Principle:

Principle #35Parameter changes

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

This design simplifies assembly, reduces material usage, and enhances electrical connectivity, resulting in a more efficient and reliable aerosol delivery system.

Implementation Method 1

a first biasing element is provided to bias the first head towards its extended position

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentEP4151101B1Aerosol delivery device/system

Publication Date: 2025.09.03 IMPERIAL TOBACCO LTD

Figure 1A~1C
Figure 2A~2B
Figure 3

AI summary

The present disclosure relates to an aerosol delivery device and system e.g. a smoking substitute device and system. In particular the present disclosure relates to an aerosol delivery device (102) comprising at least one connector pin (20a, 20b), the connector pin having a main body (27), a first head (21a, 21b) for electrical connection to an aerosol delivery component comprising a vaporiser, and a second head (22a, 22b) for electrical connection to an electrical component within the device, wherein both the first and second heads are biased to extend from the main body.