Non-Round Electrical Connector Rotation Inhibition
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Solution Overview
Problem
Existing electrical connectors for printed circuit boards (PCBs) face issues with rotation during installation and potential damage due to the use of round busbars and screws, which can lead to mechanical stress and vibration-induced problems.
Innovation Solution
The design features a conductive body with a non-round external profile and a round aperture to prevent rotation, combined with a conductive stud and nut system that mechanically and electrically connects to the PCB, using a cylindrical sleeve with projections to inhibit rotation and a flange with a bonding surface for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a round busbar and screw are used for connection, then the manufacturing is simple and cost-effective, but rotation during installation occurs and mechanical stress and vibration-induced problems arise
Solution Approach 1:
The connector body employs a non-circular cross-sectional shape (such as oval, rectangular, or triangular) that corresponds to a non-circular aperture in the PCB. This asymmetric geometry prevents rotation during installation and operation, eliminating the reliability issues associated with round busbars while maintaining manufacturing simplicity through standard forming processes
2Reliability
If a non-round external profile is used to inhibit rotation, then connection stability improves, but the manufacturing complexity increases
Solution Approach 1:
The non-circular cross-sectional shape is integrated into the basic connector body geometry rather than being added as a separate complex mechanism. Common shapes like oval or rectangular profiles are used, which can be manufactured using standard extrusion or forming processes, thus achieving rotation inhibition without significantly increasing manufacturing complexity
3Strength
If a screw fastening system is used, then mechanical connection is achieved, but the risk of PCB damage and vibration-induced stress increases
Solution Approach 1:
The screw fastening system is completely removed from the connector design. Instead, the connector relies on friction fit, interference fit, or snap-fit mechanisms inherent in the non-circular geometry and material properties, eliminating the harmful effects of screw holes and fastening operations on the PCB while maintaining adequate mechanical strength
Data Source
AI summary
An electrical connector is provided with a conductive body sized to be inserted into a printed circuit board (PCB) aperture. The body has an external profile that is not round to inhibit rotation relative to a corresponding aperture in the PCB. The body has a round aperture formed therein for receipt of an elongate conductive fastener. A circuit board assembly is provided with a PCB aperture that is not round for receipt of the connector. A circuit housing assembly is provided with a housing with an aperture. A conductive stud extends through the PCB aperture and the housing aperture. A conductive nut is mounted on the stud adjacent to the connector. A vehicle power interface is provided with a power supply with a conductive connector received upon the stud on an external side of the housing. A conductive nut is mounted on the stud adjacent to the power supply connector.