PCB High-Power Tab-and-Slot Coil Interconnect Without Soldering

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Solution Overview

Problem

Current high amperage printed circuit boards face challenges with high-cost, custom connectors that occupy significant space and require high heat for soldering or welding, leading to reduced reliability and limited circuit placement.

Innovation Solution

A connector configuration using electrically conductive tabs and slots with helical spring elements, where the spring elements are compressed between the tab and slot to form a conductive path, eliminating the need for soldering or welding and allowing for increased conduction area and reduced heat absorption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If custom connectors are used for high amperage applications, then electrical conduction capability is improved, but cost increases and manufacturing complexity increases

Engineering Contradiction:

Improveelectrical conduction capabilityVSAvoidconnector customization

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The copper inlay itself serves as the connector, eliminating the need for separate custom connector components. The PCB structure provides its own electrical connection capability through the embedded copper inlay that extends to the board edge, making the system self-sufficient and reducing external dependency on specialized connectors.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The connector function is merged with the PCB structure by embedding copper inlays directly into the board. This integration combines the circuit trace function with the connector function, eliminating the need for separate connector components and reducing overall system complexity.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If traditional board mounted connectors are used, then electrical connection is achieved, but board space is reduced

Engineering Contradiction:

Improveelectrical connectionVSAvoidboard space

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The connector transitions from a surface-mounted two-dimensional footprint to a three-dimensional embedded structure. The copper inlay is embedded within the PCB thickness and extends to the edge, utilizing the vertical dimension (board thickness) to provide connection capability without occupying additional surface area.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The copper inlay is nested within the PCB structure, embedded in the board thickness. This nesting allows the connector to be contained within the existing board volume rather than requiring additional external space, maximizing space utilization.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Reliability

If soldering or welding is used for large connector contacts, then electrical connection is established, but heat absorption increases and reliability decreases

Engineering Contradiction:

Improveelectrical connectionVSAvoidheat absorption

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The harmful soldering or welding process is extracted and replaced with a mechanical compression connection. The spring element applies direct mechanical force to compress the copper inlay against the mating connector, establishing electrical connection without thermal processes that could damage the PCB or surrounding components.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The thermal connection process (soldering/welding) is replaced with a mechanical compression system. The spring element provides continuous mechanical pressure to maintain electrical contact, substituting the thermal field with a mechanical field for connection establishment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 configuration reduces heat absorption, improves reliability, and frees up space on the board, while increasing the electrical conduction area and thermal performance, and allows for easy inspection and replacement of spring elements.

Implementation Method 1

a spring element wrapped around the connector tab... the spring element is compressed between the connector tab and the connector slot defining an electrically conductive path

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11824293B2Circuit board with high power interconnect conductive coil

Publication Date: 2023.11.21 HAMILTON SUNDSTRAND CORP

AI summary

A connector for an electrical assembly includes an electrically conductive connector tab extending from a first electrical component, and a spring element wrapped around the connector tab. An electrically conductive connector slot is located at a second electrical component. The connector tab is configured for insertion into the connector slot such that the spring element is compressed between the connector tab and the connector slot defining an electrically conductive path between the connector tab and the connector slot.