PCB-Insulated Conductor Connection for Lower-Cost Utility Meter Assembly
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Solution Overview
Problem
Existing conductor connection devices for utility meters are expensive to manufacture and mount due to the requirements for an insulating housing, which compromises electrical safety.
Innovation Solution
A conductor connection device with a main body having a conductor receptacle accessible through a conductor receiving opening, a contact element for connecting to a printed circuit board, and a conductor clamping element accessible from the same side as the contact element, eliminating the need for an additional insulating housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating housing is used to protect users from electricity, then electrical safety is improved, but manufacturing and mounting costs increase
Solution Approach 1:
The patent extracts the insulating function from a separate housing component and integrates it into the printed circuit board itself. The PCB's non-conductive substrate serves as the insulating element, eliminating the need for an additional insulating housing while maintaining electrical safety and reducing manufacturing complexity.
Solution Approach 2:
The printed circuit board is assigned multiple functions: it provides electrical connections through contact elements, structural support through its rigid substrate, and electrical insulation through its non-conductive material. This multi-functionality eliminates the need for separate insulating housing components.
2Reliability
If the conductor clamping element is accessible from the opposite side of the contact element, then electrical isolation is improved, but device complexity and mounting difficulty increase
Solution Approach 1:
The patent resolves the spatial conflict by transitioning to a different dimensional arrangement. Instead of placing the clamping element on the opposite side of the PCB (which would require complex through-board routing), both the contact element and clamping element are positioned on the same side, utilizing the lateral dimension of the PCB surface. This maintains electrical isolation through the PCB substrate while simplifying the overall device structure.
Data Source
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AI summary
The invention relates to a conductor connection device (1) with a contact element (6) at one side (7) thereof, a printed circuit board (2) with the conductor connection device (1), and a utility meter (20) with the printed circuit board (2). In order to reduce production costs of the conductor connection device (1) without increasing the production costs of the printed circuit board (2) or the utility meter (20) and without affecting operational safety, the conductor connection device (1) comprises a conductor clamping element (8) that is accessible via the second side (7) thereof, and the printed circuit board (2) comprises a through-hole (11) that is aligned with the conductor clamping element (8).