PCB Clip Contact Assembly for Low-Stress Power Connection
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Solution Overview
Problem
Existing methods for mounting printed circuit boards (PCBs) to power supplies often require complex steps, such as soldering or plugging, and can cause stress on the PCB and its mounts, leading to potential deformation and reliability issues.
Innovation Solution
A modular system with compression or friction contacts that allow for quick and stress-reduced mounting of PCBs to power supplies, using clips and rails that engage without requiring constant force, enabling easy replacement of power supplies without altering the PCB or its contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mounting methods (soldering or plugging) are used to connect PCB to power supply, then reliable electrical contact is achieved, but the process becomes complex and causes stress on the PCB leading to potential deformation
Solution Approach 1:
The mounting system is divided into separate modular components: a PCB contact with mounting features and a power supply contact with corresponding engagement features. This segmentation allows independent optimization of each component and simplifies the overall mounting process while maintaining reliable electrical contact through the modular connection interface
Solution Approach 2:
The invention replaces traditional mechanical mounting methods (soldering or plugging) with a friction-based compression contact system. The PCB contact is compressed against the power supply contact using resilient means, eliminating the need for complex soldering processes or plug insertion while maintaining reliable electrical connection through friction and compression forces
2Strength
If traditional mounting methods are used, then secure connection is achieved, but stress on the PCB and mounts causes deformation and reliability issues
Solution Approach 1:
The resilient compression means act as a counterbalancing mechanism that distributes mounting forces evenly across the contact interface. The resilient material absorbs and distributes the compression force, preventing concentrated stress points on the PCB that would lead to deformation while maintaining sufficient connection strength through distributed friction forces
Solution Approach 2:
The invention changes the mechanical parameters of the mounting system by using compression force and friction rather than rigid mechanical fastening or thermal bonding. The resilient means provide a controlled compression parameter that maintains strong electrical contact through optimized friction forces while keeping stress on the PCB within safe limits
3Ease of manufacture
If modular friction contact system is used for easy assembly, then stress on PCB is reduced, but complex resilient compression mechanisms are required
Solution Approach 1:
The resilient compression means are integrated directly into the PCB contact structure, merging the mounting function with the electrical contact function. This integration eliminates separate complex compression mechanisms while maintaining the modular friction-based contact system, allowing simple assembly through direct compression of the PCB contact against the power supply contact
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
Facilitates simple, automated assembly and disassembly of PCBs with reduced stress on the PCB and its mounts, allowing for uniform connection and easy modification of power supplies without extensive retesting, while maintaining reliable electrical contact.
Implementation Method 1
friction contacts that allow for quick and stress-reduced mounting of PCBs to power supplies
Implementation Method 2
The contact may include resilient means for compressing the PCB contact to the power supply contact
Data Source
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AI summary
In some embodiments, a power terminal is in electrical connection to a power supply terminal, and a printed circuit board is supplied with a board to power contact. Bringing the board to power contact together with the PCB contact causes an electrical connection between the power supply and the PCB. In some embodiments the electrical connection resists disconnection from the PCB contact without requiring an external force on the PCB. In some embodiments the PCB-to-power-contact and the PCB contact are brought together in a direction perpendicular to a plane of the PCB. In some embodiments the PCB-to-power-contact includes fingers with grasp the PCB contact on two sides.