Modular Electronic Media System With Solderless Actuator Coupling
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Solution Overview
Problem
The production of electronic media devices in high-cost jurisdictions is hindered by long production lead times due to the need for complex assembly of components, which requires technical skills not commonly available in the industry, leading to inefficiencies and increased costs.
Innovation Solution
An electronic media production system comprising modular components that can be coupled without soldering, using actuators and connectors such as pin-socket, USB ports, and various sensors, allowing for quick assembly and operation by selecting appropriate components from an inventory and programming OTP chips for specific functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional soldering assembly methods are used, then reliable electrical connections are achieved, but production lead times increase and manufacturing complexity increases
Solution Approach 1:
The device is divided into separate modular components (display module, audio module, sensor module, etc.) that can be independently assembled and tested before final integration. This segmentation allows parallel processing and reduces the time required for complete assembly while maintaining connection reliability through standardized interfaces.
Solution Approach 2:
Components are pre-assembled into sub-modules with pre-tested electrical connections before final device assembly. This preliminary action ensures reliable connections are established in advance, reducing on-site assembly time and allowing for quality control to be performed earlier in the manufacturing process.
2Reliability
If traditional soldering assembly methods are used, then reliable electrical connections are achieved, but manufacturing complexity and skill requirements increase
Solution Approach 1:
The complex soldering process is extracted and replaced with simplified mechanical connection methods such as snap-fit connectors, magnetic attachments, or press-fit terminals. This extraction eliminates the need for skilled soldering while maintaining reliable electrical connections through mechanically robust interfaces that are easier to assemble and disassemble.
Solution Approach 2:
Standardized connector interfaces act as intermediaries between different modules, providing a universal language for electrical connections. These intermediaries simplify the assembly process by eliminating the need for custom soldering connections and reducing the skill level required while maintaining reliable signal and power transmission.
3Productivity
If components are assembled without soldering, then assembly speed increases and skill requirements decrease, but connection reliability may be compromised
Solution Approach 1:
Multiple connection functions are merged into single integrated connectors that simultaneously provide electrical connectivity, mechanical attachment, and alignment features. This merging eliminates the need for separate soldering and mechanical fastening steps, achieving both high assembly speed and reliable connections through a single operational step.
Solution Approach 2:
The connection system incorporates dynamic features such as spring-loaded contacts, magnetic latching, or interlocking mechanisms that automatically ensure reliable electrical contact during assembly. These dynamic features adapt to manufacturing tolerances and ensure consistent connection reliability without requiring precise manual alignment or soldering skills.
Data Source
AI summary
A system comprising modules. Each module includes: a presentation system including one or more of a speaker and a video screen; and a port. In use, if the presentation system includes the speaker, the system produces sounds derived from data obtained via the port. If the presentation system includes the screen, the system displays images derived from data obtained via the port. The module can also include connectors and the system can also include actuators. Each actuator, in use, can be coupled without soldering to a connector, and the presentation system of each module can operate in response to the actuator or actuators coupled to said each module. The system can also include data storage devices, each adapted to be releasably coupled to a respective port, and the port can be selected from: microchip socket and USB port. The system can be used as part of a method.