PCB Tab-Guided Connector Layout for Polarity-Protected Inverters

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Solution Overview

Problem

Conventional electrical systems face challenges in ensuring a secure, mechanically protected, and polarity-protected connection between printed circuit boards, particularly in inverters or converters.

Innovation Solution

The implementation of a dual printed circuit board system where the first board features protruding tab regions that guide and protect contact pins inserted into holes on the second board, with irregular spacing of tab regions preventing reverse polarity and ensuring correct alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If contact pins are inserted directly into holes without guidance, then the connection process is simple, but the contact pins lack mechanical protection and may be damaged during insertion

Engineering Contradiction:

Improvemechanical protection of contact pinsVSAvoidstructure of connection interface

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The tab regions are designed to protrude before the contact pins, performing the guidance action in advance. When the first PCB is inserted into the second PCB, the tab regions enter the recesses first, establishing the correct alignment and providing mechanical protection for the subsequent insertion of contact pins into holes.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If tab regions are added to guide contact pins, then mechanical protection is improved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveguidance of contact pinsVSAvoidproduction of printed circuit board

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The tab regions are integrated directly into the PCB structure during the manufacturing process, merging the guidance function with the board itself. This eliminates the need for separate guidance components and reduces assembly steps, as the tab regions are formed as part of the PCB fabrication process through material removal or addition.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If tab regions are spaced regularly, then the design is simple, but reverse polarity connection is possible

Engineering Contradiction:

Improveprevention of reverse polarityVSAvoidspacing pattern of tab regions

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The tab regions are positioned at irregular intervals along the connection edge, creating an asymmetric pattern that is sensitive to rotation. This asymmetric spacing ensures that only the correct orientation of the first PCB relative to the second PCB allows all tab regions to align with their corresponding recesses, thereby preventing reverse polarity connections.

Inventive Principle:

Principle #4Asymmetry

4Reliability

If multiple components are used for connection, then the connection is secure, but the number of parts increases

Engineering Contradiction:

Improvesecurity of connectionVSAvoidnumber of connection elements

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The connection system combines multiple functions into integrated structures: the tab regions serve both as mechanical guides and as structural elements that define insertion direction, while the recesses provide both alignment and mechanical retention. This merging reduces the need for separate guidance features, retention clips, or alignment marks, thereby reducing the total number of parts.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12309927B2Electrical device, in particular inverter or converter

Publication Date: 2025.05.20 SEW EURODRIVE GMBH & CO KG

AI summary

An electrical device, e.g., an inverter or converter, includes a first and a second printed circuit board. The first printed circuit board includes protruding tab regions, and a respective tab region protrudes into a respective recess of the second printed circuit board. Contact pins, e.g., of one or more plug connector parts, protrude into holes of the second printed circuit board.