PCB Power Connector Assembly Using Mandrel Press Contact
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Solution Overview
Problem
The assembly and installation of high-current connectors on printed circuit boards can cause damage due to mechanical forces and result in faulty solder connections, which are prone to disruption by temperature fluctuations.
Innovation Solution
A power connection device with a first connecting element and a mandrel-shaped second connecting element that minimizes mechanical stress on the circuit board by using sliding surfaces and a predetermined breaking connection, eliminating the need for solder and ensuring a reliable electrical contact even at high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-current connectors are assembled to the printed circuit board using conventional methods, then electrical connection is established, but mechanical forces during assembly can damage the brittle circuit board
Solution Approach 1:
The connecting element is divided into two separate parts: a first connecting element that is inserted into the contact opening and a second connecting element that is pressed against it. This segmentation allows the assembly process to occur in two stages, reducing the mechanical stress on the circuit board during insertion while maintaining reliable electrical connection through the contact between the two elements.
Solution Approach 2:
The first connecting element is inserted into the contact opening beforehand, establishing a preliminary position. Then the second connecting element is pressed against it to complete the electrical connection. This preliminary action allows the circuit board to accommodate the first element without excessive force, preventing damage while ensuring reliable connection.
2Reliability
If high-current connectors are soldered to electrical contacts on conductor tracks, then electrical connection is established, but solder connections can be interrupted by temperature fluctuations
Solution Approach 1:
The soldering process and solder material are completely removed from the connection system. Instead of using solder to join the connector to the electrical contacts, the patent uses a direct mechanical press connection between the first and second connecting elements. This extraction eliminates the vulnerability to temperature-induced solder melting while maintaining reliable electrical connection.
Solution Approach 2:
The chemical-thermal joining method (soldering) is replaced with a purely mechanical pressing system. The electrical connection is established through direct mechanical contact between conductive surfaces under pressure, which is resistant to temperature fluctuations. This substitution eliminates the temperature sensitivity inherent in soldered joints.
3Productivity
If conventional assembly methods are used for high-current connectors, then electrical connection is achieved, but assembly time is increased and damage risk is higher
Solution Approach 1:
The assembly process is segmented into two simple, rapid steps: insertion of the first element and pressing of the second element. This segmentation eliminates complex alignment and soldering operations, significantly reducing assembly time while maintaining high reliability through the predetermined breaking connection that ensures proper assembly.
Solution Approach 2:
The connection mechanism transitions from a permanent soldered state to a controllable mechanical press connection with a predetermined breaking point. This parameter change allows for rapid assembly and disassembly while ensuring reliable electrical connection during use, improving both productivity and assembly reliability.
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 device allows for easy and damage-free assembly, reduces assembly time, and maintains a stable electrical connection without solder melting, minimizing circuit board damage and connection failures.
Implementation Method 1
an outer sliding surface which presses the inner sliding surface of the first connecting element inserted into the contact opening of the printed circuit board outwards to establish an electrical contact
Data Source
Figure 1A~1D
Figure 2A~2D
Figure 3A~3B
AI summary
Current connector (1) for a circuit board (2), having a first connection element (1A) with an outer contact face (11), which is insertable into a corresponding contact opening (3) of the circuit board (2), and an inner slide face (7), and having a second connection element (1B) which has a mandrel-shaped portion (6) with an outer slide face (8) which presses the inner slide face (7) of the first connection element (1A), inserted into the contact opening (3) of the circuit board (2), outwards in order to produce an electrical contact between the contact face (11) of the first connection element (1A) and a contact face (9) of the contact opening (3) of the circuit board (2), as soon as the outer slide face (11) of the mandrel-shaped portion (6) of the second connection element (1B) is pressed against the inner slide face (7) of the first connection element (1A).