PCB-Mounted High Voltage AC Receptacle With Parallel Insertion Axis
Solution Overview
Problem
Existing electrical power distribution systems face challenges in incorporating high voltage AC outlets on printed circuit boards (PCBs), which require mechanical strength and higher power capacity due to higher plug insertion and removal forces compared to low voltage DC outlets.
Innovation Solution
The solution involves mounting high voltage AC electrical receptacles to a PCB with at least two electrical conductors, where the receptacles are mechanically and optionally electrically coupled to the PCB, featuring electrical contacts that define an insertion axis parallel to the PCB, and optionally including low voltage DC receptacles with converter circuitry for power conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high voltage AC electrical receptacles are mounted to a PCB using traditional techniques with butt splices and threaded fasteners, then the mechanical strength and power capacity are sufficient, but the assembly becomes bulky and complex
Solution Approach 1:
The patent combines multiple separate components (receptacle, conductors, mounting structure) into a single integrated PCB-mounted unit. The receptacle is directly mounted to the PCB with electrical conductors already positioned and connected, eliminating the need for separate butt splices and threaded fasteners. This merging reduces assembly complexity while maintaining mechanical strength through the unified structure.
2Power
If high voltage AC electrical receptacles are mounted to a PCB using traditional techniques, then the power capacity is sufficient, but the housing becomes bulky
Solution Approach 1:
The patent reorients the receptacle insertion axis to be substantially parallel to the PCB rather than perpendicular. This dimensional change allows the receptacle to be mounted in a planar configuration on the PCB, significantly reducing the housing volume required while maintaining full power capacity. The electrical conductors are arranged to connect along the PCB surface, enabling this compact layout.
3Volume of stationary object
If high voltage AC electrical receptacles are mounted to a PCB, then the device becomes compact, but the mechanical strength must accommodate higher plug insertion and removal forces
Solution Approach 1:
The patent incorporates reinforcement structures and robust mounting features directly into the PCB and receptacle assembly during manufacturing. The electrical conductors are pre-positioned and secured with adequate mechanical strength, and the receptacle is firmly attached to the PCB before final assembly. This preliminary preparation ensures the structure can withstand high plug insertion and removal forces without requiring bulky housing.
Data Source
AI summary
An electrical receptacle assembly includes an electrically insulative board, such as a silicon-based printed circuit board (PCB), with electrical contacts mounted to the board to form a high voltage AC receptacle configured to receive a male plug associated with an electrical consumer. The electrical contacts may be mechanically connected directly to the board and receive electrical power from respective wires fitted with terminal connectors, or may be supported in receptacle assemblies that receive electrical power from conductors embedded in the board. Optionally, the electrical contacts are mounted directly to a separate receptacle board that extends outwardly from a main board. A low voltage receptacle and associated circuitry may be incorporated into the receptacle assembly, which may further include an outer housing to facilitate mounting in a work area or the like.