PCB Module Layout With Conductor Bodies for Portable Power Tools
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Solution Overview
Problem
Portable electrical machines, such as hand-held power tools and suction devices, face challenges in transmitting higher voltage supply and ground potentials due to the unsuitability of printed circuit board conductor tracks, requiring larger conductor cross-sections and separate wiring lines which complicates the wiring and assembly process.
Innovation Solution
A printed circuit board module configuration with an intermediate body and a base body, featuring conductor bodies with larger cross-sections that connect to the printed circuit board, allowing for simplified transmission of supply, ground, and protective conductor potentials, and incorporating a guide body arrangement that facilitates assembly and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conductor tracks of the printed circuit board are used for supply voltages and ground potentials, then the wiring is simplified, but the conductor cross-section is too small for higher voltage levels
Solution Approach 1:
The patent combines the functions of conductor tracks and separate wiring by integrating conductor bodies directly onto the printed circuit board. The conductor bodies are formed as integral extensions of the PCB structure, merging the advantages of both trace-based and wire-based connections into a single unified system that provides both low impedance paths and mechanical robustness.
Solution Approach 2:
The invention transitions from two-dimensional conductor tracks on the PCB surface to three-dimensional conductor bodies that extend vertically through the board structure. This dimensional change allows conductor bodies to provide larger cross-sectional areas for current carrying while maintaining compact integration with the PCB, effectively solving the limitation of trace thickness.
2Reliability
If separate wires or stranded wires are used for higher potentials, then the conductor cross-section is sufficient, but the wiring and assembly process becomes more complex
Solution Approach 1:
The patent merges separate wiring operations into a single integrated PCB manufacturing process. Conductor bodies are formed using standard PCB fabrication techniques such as plating and lamination, eliminating the need for separate wire attachment steps and reducing assembly complexity while maintaining robust electrical connections.
Solution Approach 2:
The conductor bodies are self-formed as part of the PCB structure through automated manufacturing processes. The PCB fabrication process itself creates the conductor bodies without requiring additional manual wiring operations, allowing the structure to serve its own wiring function and eliminating complex assembly steps.
3Reliability
If multiple separate lines are provided for potentials requiring connection at several points, then the electrical connection is reliable, but the device complexity increases
Solution Approach 1:
The conductor bodies are designed to serve multiple functions simultaneously: they provide power distribution, ground connections, and mechanical support structures. Each conductor body can be accessed at multiple locations along its length, eliminating the need for separate lines to reach different points and reducing overall system complexity.
Solution Approach 2:
The conductor bodies are segmented into accessible sections that can be connected to different components at various locations. This segmentation allows a single continuous conductor body to serve multiple connection points, reducing the number of separate lines needed while maintaining reliable electrical connections throughout the system.
Data Source
Figure 1~2
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Figure 4~6
AI summary
The portable electric machine has a circuit board module (210), which has a printed circuit board (123). Electrical components (211) are arranged at the conducting paths and over the conducting paths. The electrical components are electrically connected together. A guide body arrangement (243) is arranged at a surface side (218) or another surface side (219) of the printed circuit board with guide bodies (238 to 242) separated by the printed circuit board.