Expandable Cylindrical Connector Fills Air Gaps for High Current
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Solution Overview
Problem
Conventional connectors often fail to efficiently transfer high current between circuit boards due to air gaps that limit the conductive surface area, restricting the amount of power that can be transferred.
Innovation Solution
The use of an expandable cylindrical connector with a malleable material, such as copper, silver, or nickel, that expands to fill air gaps between the connector and the plated barrel of the circuit board, increasing the conductive surface area by applying force with fasteners or phalanx-type washers to ensure effective contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a conventional connector is used to connect two circuit boards, then the connection is simple and quick, but the conductive surface area is limited due to air gaps, restricting current transfer capability
Solution Approach 1:
The connector employs a spring mechanism that dynamically adjusts the contact pressure between the connector and the plated barrel. The spring-loaded design allows the connector to maintain optimal contact force while accommodating manufacturing tolerances and board thickness variations, ensuring maximum conductive surface area contact without requiring precise manual adjustment
Solution Approach 2:
The patent changes the physical state of the connector by introducing a spring-loaded mechanism that varies the contact pressure parameter. This dynamic parameter adjustment allows the connector to compensate for air gaps and maintain consistent electrical contact, thereby increasing the effective conductive surface area and current transfer capability
2Power
If the conductive surface area is increased to transfer high current, then power transfer capability improves, but the connector complexity increases
Solution Approach 1:
The connector is segmented into distinct functional components: a spring mechanism for applying contact force, a conductive element for current transfer, and a mounting structure for board attachment. This segmentation allows each component to be optimized independently while working together to achieve high power transfer capability without excessive overall complexity
Solution Approach 2:
The spring-loaded connector design serves multiple functions simultaneously: it applies contact pressure to eliminate air gaps, accommodates manufacturing tolerances, maintains consistent electrical contact, and provides mechanical retention. This multi-functionality reduces the need for additional components, thereby limiting the increase in overall device complexity
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 solution enables the transfer of high current between circuit boards by reducing or eliminating air gaps, allowing 50% or more of the plated barrel to be conductively connected, thereby enhancing the power transfer capability.
Implementation Method 1
a malleable cylindrical portion, such as copper, silver, or nickel, that expands to fill air gaps between the connector and the plated barrel
Implementation Method 2
enables the transfer of high current between circuit boards by reducing or eliminating air gaps, allowing 50% or more of the plated barrel to be conductively connected
Data Source
AI summary
A system and apparatus for increasing connectivity of a circuit board comprising a connector, wherein the connector has a horizontal body and a hollow cylindrical portion extruding vertically from the body; wherein the cylindrical portion is made up of a set of pieces; wherein at least a piece of the set of pieces is arranged to expand horizontally, upon insertion of a phalanx head in a vertical manner. A method to increase current connectivity comprising screwing a fastener into threads of a connector through a hollow cylindrical portion of the connector; wherein the hollow cylindrical portion of the connector is made up of a set of pieces; wherein the screwing causes a phalanx head to contact the cylindrical portion expanding at least one piece of the set of pieces in a horizontal manner in relation to the fastener.