PCB Tap Assembly With Sliding Contacts for Linear Power Distribution
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Solution Overview
Problem
Existing tap designs for linear power distribution arrangements are complex, costly, and require individual integration and wiring of contact elements, making them difficult to manufacture and reposition.
Innovation Solution
A compact tap design using a circuit board with predefined connections and movable contact elements on current bridges, which are soldered, plugged, or screwed onto the board, eliminating the need for individual wiring and allowing easy repositioning of contact elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual contact elements are used in the tap, then the tap can contact conductors of linear supply units, but the manufacturing complexity and material expenditure increase significantly
Solution Approach 1:
Multiple individual contact elements are merged into a single printed circuit board assembly. The PCB integrates multiple contact points (pads, vias, traces) that collectively perform the contact function, eliminating the need for separate contact elements and their individual wiring.
Solution Approach 2:
The mechanical wiring and connection system for individual contact elements is replaced by conductive traces and solder joints on the PCB. The electrical connections are established through standardized PCB manufacturing processes rather than manual wiring.
2Reliability
If individual contact elements with separate wiring are used, then contact with conductors is achieved, but the space requirements and manufacturing cost increase
Solution Approach 1:
The contact elements and their wiring are combined into a single integrated PCB structure. The conductive traces on the PCB serve as the wiring, eliminating the need for separate wire harnesses and reducing overall material usage.
Solution Approach 2:
The physical form and electrical properties of the wiring are changed by using conductive traces deposited on the PCB substrate rather than traditional insulated wires. This reduces the volume and mass of wiring materials required.
3Reliability
If contact elements are individually integrated and wired, then the tap functions properly, but repositioning becomes difficult and time-consuming
Solution Approach 1:
The PCB is designed as a flexible or reconfigurable platform where contact elements can be repositioned. This may involve using flexible PCB materials, reworkable solder joints, or modular contact modules that can be moved to different locations on the board.
Solution Approach 2:
The PCB is segmented into multiple functional areas with standardized contact patterns, allowing individual contact elements to be relocated to different segments while maintaining electrical connectivity through the PCB's conductive network.
4Length of stationary object
If multiple power guide profiles are connected to achieve longer length, then the power distribution coverage increases, but the device complexity and connection points increase
Solution Approach 1:
The PCB-based tap is designed with universal contact patterns and standardized interfaces that can work with multiple power guide profile configurations. This universality simplifies the connection process when extending power distribution over longer distances by reducing the complexity of interconnections.
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
This design simplifies production, reduces material costs, and allows for easy reconfiguration of contact elements, eliminating the need for additional wiring and space, while integrating electronic components for signal processing.
Implementation Method 1
the contact elements comprise spring elements that generate a spring force perpendicular to the plane of the circuit board and in the direction of the conductors of the linear supply units, thus pressing the contact elements against the conductors
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A tap for a linear current distribution arrangement comprising a printed circuit board (2), a number of current bridges (4) extending perpendicular to the plane of the printed circuit board, and a number of contact elements (6) is to be manufactured in a particularly compact, cost-effective, and lightweight manner, and designed so that the position of the contact elements can be changed particularly easily. For this purpose, the contact elements (6) are arranged to be slidably mounted on and along the current bridges (4), and the contact elements (6) include spring elements that allow movement of the contact elements (6) perpendicular to the plane of the printed circuit board.