PCB Charging Contacts for 360-Degree Audio Docking
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Solution Overview
Problem
Designing electronic devices, such as portable audio devices, to interface with charging docks adds complexity and cost, and requires precise axial alignment, which detracts from the user experience and increases the risk of misalignment leading to failed charging.
Innovation Solution
Forming charging contacts on a printed circuit board (PCB) as an external surface of the device, allowing 360-degree mateability with a charging dock, eliminating the need for custom connector blocks and reducing the device's form factor while ensuring proper charging regardless of orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom connector blocks are used for charging docks, then charging connection reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the charging contact functionality directly into the existing PCB structure by exposing traces on the PCB surface, eliminating the need for separate custom connector blocks. This integration reduces device complexity while maintaining charging connection reliability through direct electrical contact between the PCB traces and charging dock contacts.
Solution Approach 2:
The PCB serves multiple functions: it provides structural support, electrical connectivity, and charging contact interface. By making the PCB surface itself the charging interface, the component serves universal purposes rather than requiring dedicated specialized connectors, thereby reducing overall device complexity.
2Reliability
If precise axial alignment is required for charging docks, then charging connection reliability is improved, but ease of operation deteriorates
Solution Approach 1:
The patent transitions from requiring precise axial alignment (one-dimensional alignment) to allowing 360-degree rotational placement (two-dimensional flexibility). By arranging charging contacts in a circular pattern on the PCB surface, the device can be placed on the charging dock in any rotational orientation, eliminating the need for precise axial alignment while maintaining reliable electrical contact.
Solution Approach 2:
The circular arrangement of charging contacts breaks the traditional symmetric axial alignment requirement. This asymmetric radial configuration allows the charging interface to function reliably regardless of rotational orientation, significantly improving ease of operation.
3Ease of manufacture
If charging contacts are exposed on PCB surface, then ease of manufacture is improved, but contacts become vulnerable to environmental damage
Solution Approach 1:
The patent applies a conformal coating (thin film) over the exposed PCB charging contacts to protect them from environmental factors such as moisture, oxidation, and corrosion. This coating maintains the electrical conductivity needed for charging while providing a protective barrier against environmental damage.
Solution Approach 2:
The charging contact structure becomes a composite of the PCB trace material (e.g., copper) and the protective coating material (e.g., conformal coating polymer). This composite structure combines the electrical conductivity of the metal trace with the environmental protection of the coating, addressing both manufacturing ease and environmental vulnerability.
Data Source
AI summary
An audio device with charging contacts on a printed circuit board (PCB) is described herein. In some implementations, the charging contacts are on a surface of the PCB that is a bottom external surface of the audio device, thereby eliminating the need for a custom connector block. Thus, cost and height savings can be realized. In some implementations, the charging contacts are designed to enable 360 degree docking ability with a charging dock. This can be achieved using one or more ring-shaped charging contacts that make physical contact with spring-loaded pins on the charging dock in any relative axial alignment. In some implementations, the audio device includes a mating feature configured to mate with a mating feature of the charging dock to help ensure a proper charging connection is made and to help physically center the audio device relative to the charging dock.