Low-Profile PCB-Mounted Contactor with Lateral Contact Movement
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Solution Overview
Problem
Conventional PCB-mounted contactors are bulky and tall, causing packaging constraints in electrical assemblies, and traditional mounting methods interfere with adjacent PCB slots, limiting the number of components that can be installed.
Innovation Solution
A low-profile PCB-mounted contactor design with a planar surface, where the contact moves parallel to the surface, utilizing a linear or pivot actuator, and includes a solenoid or pivot mechanism to minimize height and avoid overlapping adjacent slots, allowing for improved packaging and reduced height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional contactors are surface mounted to PCB, then connectivity between contactor and PCB is provided, but height of housing increases and interferes with installation envelope of other components
Solution Approach 1:
The contactor design transitions from vertical mounting (perpendicular to PCB) to horizontal mounting (parallel to PCB surface). The contactor housing is positioned in the plane of the PCB rather than extending vertically, fundamentally changing the dimensional orientation to resolve the height conflict while maintaining electrical connectivity through lateral connection points.
Solution Approach 2:
The contactor is nested within the PCB footprint by positioning it in the plane of the board. The housing and switching elements are contained within the lateral boundaries of the PCB, allowing the contactor to be integrated into the PCB assembly without protruding vertically and interfering with other components stacked in the vertical direction.
2Length of stationary object
If contactor height is reduced for better packaging, then installation envelope is improved, but movement envelope of switch element and drive elements is constrained
Solution Approach 1:
The switching mechanism transitions from vertical movement (up and down) to lateral movement (side to side) parallel to the PCB surface. This dimensional change allows the contact elements to open and close while remaining within the constrained vertical space, as the movement occurs in the horizontal plane where space is abundant.
Solution Approach 2:
The contactor employs a dynamic lateral switching mechanism where the contact elements move horizontally to make and break electrical connections. This dynamic lateral motion provides sufficient movement envelope for reliable switching while maintaining a compact vertical profile, as the switching action occurs parallel to the PCB rather than perpendicular to it.
3Length of stationary object
If contactor is discretely mounted with wiring harness, then packaging constraints are reduced, but device complexity and installation time increase
Solution Approach 1:
The contactor is merged with the PCB by positioning it in the plane of the board and establishing electrical connections through lateral contact points rather than vertical sockets. This integration eliminates the need for separate mounting brackets, wiring harnesses, and vertical connectors, reducing overall system complexity while maintaining packaging efficiency.
Solution Approach 2:
The PCB serves multiple functions: it provides both the structural mounting platform and the electrical connection pathway for the contactor. By integrating the contactor in the PCB plane with lateral connections, the PCB simultaneously supports mechanical mounting and electrical connectivity, eliminating the need for separate mounting hardware and wiring harnesses.
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
The low-profile design enables the contactor to be seated within card racks without overlapping adjacent slots, increasing the number of PCBs that can be installed and improving thermal management and switching speed.
Implementation Method 1
The linear actuator can include a solenoid with a coil and a plunger
Implementation Method 2
The coil can be fixed relative to the PCB. The plunger can be fixed relative to the contact and can extend through the coil
Implementation Method 3
The pivot actuator can include a coil, a core, and a permanent magnet
Implementation Method 4
The coil can be fixed relative to the PCB. The core can extend through the coil. The core can be fixed to the PCB. The permanent magnet fixed to the contact
Data Source
AI summary
A printed circuit board (PCB)-mounted contactor including a PCB with planar surface, source and load terminals fixed to the PCB, and a contact. The contact is supported by the PCB and is movable between open and closed positions. Movement of the contact is parallel to the planar surface. Electrical assemblies having PCB-mounted contactors and methods of controlling current flow in electrical systems with PCB-mounted contactors are also described.