Housing Electrical Connector with Integrated PCB Connection Pad
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Solution Overview
Problem
Existing electrical connectors for high-current applications are bulky and expensive, with unreliable connections due to high electrical resistance and susceptibility to corrosion, especially when dealing with currents greater than ten amperes.
Innovation Solution
The design features a reduced-size connection pad on the external face of the box, utilizing a printed circuit board with a power plane and ground plane, surface-mounted capacitors for improved electromagnetic filtration, and conductive crosspieces for reliable current passage, along with a removable fixing mechanism to ensure reproducible and reliable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connectors with screws, nuts and metal bases are used for high-current applications, then reliable electrical connection can be achieved, but the connector becomes very bulky and expensive
Solution Approach 1:
The invention merges the electrical connection function directly into the housing structure by integrating connection pads on the housing walls, eliminating the need for separate metal bases and reducing the number of components. This integration maintains reliable electrical connection while significantly reducing connector volume and complexity.
Solution Approach 2:
The invention extracts the essential electrical connection function from the complex traditional connector assembly (screw, nut, metal base) and implements it through simplified connection pads integrated into the housing, removing unnecessary structural elements while preserving the core electrical connection capability.
2Reliability
If traditional connectors with multiple components are used, then electrical connection can be established, but the complexity and cost of the connector increase
Solution Approach 1:
The invention combines multiple traditional connector components (housing, connection pads, mounting structure) into an integrated assembly where the housing itself provides the mounting structure and electrical connection interface, eliminating the need for separate metal bases and reducing overall complexity.
Solution Approach 2:
The housing structure serves multiple functions: it provides mechanical protection, structural support, and integrated electrical connection interfaces. This multi-functionality eliminates the need for separate dedicated connector components, reducing complexity while maintaining reliable electrical connection.
3Reliability
If large contact surface is used between terminal and support surface, then electrical resistance is limited, but the connector protrudes well beyond the outer face of the case
Solution Approach 1:
The invention transitions from a protruding three-dimensional connector structure to a planar connection pad design that lies flush with the housing outer face. The electrical connection interface is arranged in the plane of the housing surface rather than extending perpendicular to it, eliminating excessive protrusion while maintaining adequate contact surface area for low electrical resistance.
4Reliability
If electrical contact is established via nut and screw threads, then connection can be made, but the wiring resistance depends on tightening torque and surface conditions making it difficult to reproduce
Solution Approach 1:
The invention replaces the mechanical screw-and-nut thread engagement system with a direct contact pad interface that relies on planar surface contact rather than threaded mechanical fastening. This substitution eliminates the sensitivity to tightening torque and thread surface conditions, providing more reproducible and stable electrical resistance characteristics.
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 provides a cost-effective, compact, and reliable electrical connection with reduced impedance and improved electromagnetic compatibility, minimizing the dependence on clamping force and surface conditions for long-term performance.
Implementation Method 1
at least one printed circuit board arranged on an outer face of one of these walls and forming part of this wall, this printed circuit board having an outer face and an inner face, this printed circuit board making it possible to establish an electrical connection between an external cable and the electronic components housed inside the casing
Implementation Method 2
positioning a capacitor between the power plane and a ground plane etched on the same printed circuit board helps limit parasitic wiring inductances of that capacitor, ultimately improving electromagnetic filtration common mode
Implementation Method 3
the use of several conductive crosspieces connecting the external and internal planes allows to ensure a reproducible and reliable passage of current over time
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a housing, including: electronic components (42); walls (44) mechanically insulating said electronic components from the outside; at least one electric connection pad (18, 20, 22, 24) arranged on an outer surface of one of said walls so as to be electrically coupled to a cable outside the housing, said connection pad being electrically coupled to the electronic components (42) inside the housing, characterised in that the connection pad includes: a printed circuit board (50) defining a portion of the housing wall (44) and having a surface exposed to the outside of the housing; and an electric connection outer plane (60, 62) engraved on said surface for directly contacting the outer cable, said plane being electrically coupled to the electronic components.