Electronics Module Ground Contact DIN Rail Mounting

Solution Overview

Problem

Existing electronics modules for industrial automation controllers and I/O modules face issues with high impedance and durability due to suboptimal ground connectors, which are prone to contamination, vibration, and physical damage, and require additional components and manufacturing steps, increasing costs and assembly time.

Innovation Solution

An electronics module with a housing that includes a latch mechanism for DIN rail mounting, featuring an integral electrical connector with a ground contact securely connected to the connector body, providing a low impedance ground path through a single soldered connection directly to the circuit board, reducing assembly steps and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If non-soldered pressure contacts are used to connect the PCB to the ground connector, then assembly is simplified, but ground path impedance increases and reliability decreases

Engineering Contradiction:

Improveassembly simplicityVSAvoidground path reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The ground connector is merged with the electrical connector body into a single integrated component. The ground contact is formed as an integral part of the connector body, eliminating the need for separate ground connector components and their associated non-soldered pressure contacts. This integration ensures a reliable soldered connection directly to the PCB while maintaining assembly simplicity.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If intermediate circuit boards are used between the PCB and DIN rail, then grounding flexibility is improved, but component cost and assembly time increase

Engineering Contradiction:

Improvegrounding flexibilityVSAvoidassembly time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The ground connector functionality is extracted and integrated directly into the electrical connector body, eliminating the need for intermediate circuit boards. The ground contact extends from the connector body to contact the DIN rail, providing the necessary grounding flexibility without requiring additional intermediate components or assembly steps.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If separate ground connectors are individually placed and soldered to the PCB, then ground path reliability is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveground path reliabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The ground connector is merged with the electrical connector body into a single integrated component. The ground contact is formed as an integral part of the connector body, eliminating the need for separate ground connector components and their associated non-soldered pressure contacts. This integration ensures a reliable soldered connection directly to the PCB while maintaining assembly simplicity.

Inventive Principle:

Principle #5Merging (Combining)

4Productivity

If pressure contacts are used at the PCB interface, then assembly steps are reduced, but the connection becomes susceptible to contamination and vibration

Engineering Contradiction:

Improveassembly speedVSAvoidcontamination and vibration susceptibility

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The ground connector is merged with the electrical connector body into a single integrated component. The ground contact is formed as an integral part of the connector body, eliminating the need for separate ground connector components and their associated non-soldered pressure contacts. This integration ensures a reliable soldered connection directly to the PCB while maintaining assembly simplicity.

Inventive Principle:

Principle #5Merging (Combining)

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 solution ensures a reliable, durable low impedance ground path while simplifying assembly and reducing component count and manufacturing steps, enhancing the module's durability and efficiency.

Implementation Method 1

The ground contact includes a ground contact body that extends from the connector body into the housing recess and provides an electrical connection between the circuit board and the DIN rail to which the module is mounted

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentEP2685564B1Electronics module and method for providing an electronics module

Publication Date: 2019.01.23 ROCKWELL AUTOMATION TECH INC

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AI summary

An electronics module housing includes an external recess adapted to receive an associated DIN rail or other associated mounting structure. A latch mechanism is associated with the external recess and is adapted to engage the DIN rail. An electronics circuit board is located in the housing. An electrical connector is physically and electrically connected to the circuit board. The electrical connector includes: (i) a connector body; (ii) a plurality of electrical contacts secured to said connector body and comprising contact pins physically and electrically connected to the circuit board; and (iii) a ground contact secured to the connector body and including a ground pin physically and electrically connected to said circuit board. The ground contact includes a ground contact body that extends from the connector body into the housing recess. The ground contact body includes a ground contact face located adjacent The recess and adapted to contact the associated DIN rail to which the module is mounted.