Power Supply PCB Positioning via Slots and Thermoplastic Gel

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Solution Overview

Problem

Conventional outdoor power supply devices lack effective design features for positioning internal components, leading to potential damage from silicone gel injection, insulation deterioration, and high-temperature induced stress strain due to thermosetting properties.

Innovation Solution

A power supply device with PCB-positioning features and thermoplastic gel, featuring slots and protrusions for safe component placement, and a method for manufacturing using a thermoplastic gel with low viscosity to prevent component collision and stress strain.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If silicone gel is used for internal waterproof and heat dissipation, then waterproof function and heat dissipation are improved, but internal components are likely to be moved and squashed together causing damage

Engineering Contradiction:

Improvewaterproof functionVSAvoidcomponent integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

Positioning structures (protrusions and grooves) are designed in advance to secure components before silicone gel injection, preventing movement and damage during the gel filling process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The positioning structures create clearance spaces between components and casing walls, providing protective cushioning that prevents direct contact and potential damage from the silicone gel injection pressure

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Temperature

If silicone gel is used for heat dissipation, then heat dissipation performance is improved, but high-temperature induced stress strain occurs due to thermosetting property

Engineering Contradiction:

Improveheat dissipationVSAvoidstress strain

Core Design Contradiction:

TemperatureVSStress or pressure

Solution Approach 1:

The patent changes the material parameter from thermosetting silicone gel to thermoplastic gel, which does not undergo significant volume change during curing, thereby eliminating high-temperature induced stress strain while maintaining heat dissipation capability

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If no positioning design is provided for internal components, then device complexity is reduced, but components are likely to collide and be damaged during assembly

Engineering Contradiction:

Improvestructure complexityVSAvoidcomponent integrity

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The positioning function is segmented into separate protrusion and groove structures rather than using a complex integrated positioning mechanism, achieving component protection with minimal added complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Positioning protrusions and grooves act as intermediary structures that facilitate safe component placement and prevent direct collision between components during assembly

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If insulating sheets are used to prevent insulation deterioration, then insulation performance is improved, but device complexity and assembly steps increase

Engineering Contradiction:

Improveinsulation performanceVSAvoidassembly steps

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent removes the need for separate insulating sheets by integrating insulation function into the positioning structures and clearance design, simplifying assembly while maintaining insulation performance

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The positioning structures serve dual functions: both positioning components and providing insulation clearance, eliminating the need for separate insulating sheets

Inventive Principle:

Principle #5Merging (Combining)

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 solution ensures safe distances between components, eliminates the need for insulating sheets, enhances waterproof and dustproof functions, and prevents high-temperature induced stress strain, improving the reliability and stability of the power supply device.

Implementation Method 1

A gel portion is provided between the electronic elements and the casing. The gel portion includes a thermoplastic gel.

Methodology Applied

Scientific EffectFluid flow:

Implementation Method 2

a viscosity coefficient of the thermoplastic gel is smaller than 2,000 centipoises (cp)

Methodology Applied

Scientific EffectViscosity:

Implementation Method 3

The at least one pair of slots is disposed at inner walls of the casing and configured to engage the PCB for positioning the PCB

Methodology Applied

Scientific EffectMechanical engagement: Mechanical Fastener

Implementation Method 4

Some conventional outdoor power supply devices use silicone gel for internal waterproof and heat dissipation

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10986746B2Power supply device with PCB positioning function and method for manufacturing the same

Publication Date: 2021.04.20 DELTA ELECTRONICS INC(CN)

AI summary

A power supply device with PCB-positioning features includes a casing, a PCB (Printed Circuit Board) and at least one pair of slots. The casing defines an accommodating space and has at least one opening. The PCB is disposed in the accommodating space and has electronic elements thereon. The at least one pair of slots is disposed at inner walls of the casing for positioning the PCB. A gel-fillable channel is defined between the electronic elements and the inner walls of the casing.