Current Transformer Mounting via Spring-Loaded Contacts
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Solution Overview
Problem
Current transformers with soldered connections to circuit boards face challenges due to the thinness of the wire, making connections difficult to establish and prone to breakage during movement or installation.
Innovation Solution
A current transformer apparatus with a support structure featuring U-shaped electrical connectors that are biased to engage a circuit board, eliminating the need for soldered connections and allowing for easy mounting and removal without damaging the electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldered connections are used between wire ends and pins, then electrical connection is established, but the connection becomes difficult to make and prone to breakage
Solution Approach 1:
The patent replaces the traditional soldered mechanical connection with a spring-loaded electrical contact system. The spring contact applies continuous mechanical pressure to maintain electrical connection without requiring soldering, thereby eliminating the difficulties of making soldered connections while ensuring reliable electrical contact.
Solution Approach 2:
The patent changes the connection parameter from permanent soldered joint to dynamic spring-loaded contact. The spring mechanism provides continuous contact pressure and allows for easy insertion and removal, transforming the connection from a fixed state to a flexible, reusable state that improves both ease of manufacture and reliability.
2Reliability
If soldered connections are used, then electrical connection is provided, but the connection is subject to breakage during movement or installation
Solution Approach 1:
The patent introduces dynamic elements through spring-loaded electrical contacts that can flex and adapt during movement and installation. The spring mechanism absorbs mechanical stress and movement, preventing breakage while allowing easy installation and removal of the current transformer apparatus from the circuit board.
Solution Approach 2:
The spring contacts are pre-loaded to provide continuous contact pressure before any movement or installation occurs. This preliminary action ensures that the connection is already prepared to withstand movement and installation forces, preventing breakage while maintaining ease of operation.
3Adaptability or versatility
If thin wire is used for the coil, then the current transformer functions properly, but the wire is difficult to handle and connect
Solution Approach 1:
The patent introduces spring-loaded electrical contacts as intermediary elements between the thin coil wire and the circuit board pins. These contacts serve as a mediator that is easier to handle and connect than the thin wire itself, while still providing reliable electrical connection for current transformer functionality.
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
The apparatus provides a reliable, easy-to-manufacture, and easy-to-install solution for connecting current transformers to circuit boards, ensuring mechanical and electrical integrity while avoiding solder-related issues.
Implementation Method 1
The electrical connectors each include an electrical contact that is biased toward a reaction structure
Data Source
AI summary
A current transformer apparatus is configured to enable it to be electrically connected with and physically mounted to a circuit board. The current transformer apparatus includes a support upon which a coil is situated and upon which a plurality of approximately U-shaped electrical connectors are also situated. The electrical connectors each include an electrical contact that is biased toward a reaction structure. A circuit board is received between the electrical contact and the reaction structure, and the bias between the electrical contact and the reaction structure mounts current transformer apparatus to the circuit board and provides an electrical connection therebetween.