PCB Poke-In Connector Assembly for Tool-Free Surge Protection
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Solution Overview
Problem
Existing electrical connector systems require labor-intensive manual attachment of surge protection devices using wires and soldering, with splices hanging or dangling within enclosures, necessitating additional splicing steps and tools.
Innovation Solution
An electrical connector system featuring a receptacle connector with poke-in openings and mating pins that allow for direct plugging of a printed circuit board assembly, eliminating the need for separate wire attachment and mechanical mounting, and enabling quick assembly through poke-in connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wire splicing and soldering methods are used to connect surge protection devices, then reliable electrical connections are achieved, but the assembly process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent divides the connection system into modular components: a receptacle connector with integrated mounting features and a separate surge protection device with pre-attached terminals. This segmentation allows the surge protection device to be independently prepared and then quickly connected to the receptacle, eliminating the need for on-site wire splicing and soldering while maintaining connection reliability through the designed mating interface.
Solution Approach 2:
The surge protection device is pre-assembled with terminals attached to its leads before installation. This preliminary preparation of the surge protection device allows for rapid connection to the receptacle connector during installation, eliminating the need for labor-intensive wire splicing and soldering operations at the installation site while ensuring reliable electrical connections.
2Reliability
If traditional wire splicing methods are used, then electrical connections are established, but additional splicing equipment and tools are required
Solution Approach 1:
The patent extracts the complex wire splicing and soldering operations from the installation process by integrating the connection functionality directly into the receptacle connector and surge protection device assembly. The receptacle connector includes integrated mounting features and electrical contacts that directly mate with the surge protection device terminals, eliminating the need for separate splicing equipment, soldering tools, and heat shrink materials.
Solution Approach 2:
The receptacle connector and surge protection device are designed to self-connect through a plug-and-play interface. The receptacle connector includes integrated mounting features that automatically secure the surge protection device when mated, and the electrical contacts are pre-positioned to align with the device terminals, enabling the system to establish reliable connections without requiring external splicing equipment or specialized tools.
3Reliability
If manual wire attachment and soldering are performed, then secure electrical connections are achieved, but the process becomes mechanically complex and space-consuming
Solution Approach 1:
The patent merges the electrical connection function and mechanical mounting function into a single integrated receptacle connector assembly. The receptacle connector includes both the electrical contacts for signal/power transmission and integrated mounting features for mechanical attachment of the surge protection device. This combination eliminates the need for separate mechanical mounting hardware and wiring operations, reducing overall system complexity while maintaining secure electrical and mechanical connections.
4Reliability
If traditional connection methods with hanging splices are used, then electrical connections are established, but the enclosure space is wasted and organization is poor
Solution Approach 1:
The patent implements a nested arrangement where the surge protection device is directly mounted within or adjacent to the receptacle connector housing. The integrated mounting features of the receptacle connector allow the surge protection device to be securely positioned in a compact configuration, eliminating the need for separate mounting locations and preventing the creation of dangling splices that would consume valuable enclosure space. This nested arrangement optimizes space utilization while maintaining reliable connections.
Data Source
AI summary
An electrical connector system includes a receptacle connector having a receptacle housing holding receptacle contacts in contact channels with poke-in contacts. The electrical connector system includes a printed circuit board assembly coupled to the receptacle connector having a printed circuit board, an electrical component mounted to a first surface, and mating pins extending from the second surface. Each mating pin has a mating end plugged into poke-in openings of the receptacle housing to electrically connect the mating pins to the poke-in contacts of the receptacle connector.