Releasable Pedal Connector Assembly for Modular Circuit Replacement
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Solution Overview
Problem
Conventional connector assemblies lack independent protection for circuit boards and electrical components, requiring entire assembly replacement upon component failure, which is costly and time-consuming, and offer limited versatility in application.
Innovation Solution
A connector assembly with a circuit board and terminal pins, encased by a first material layer and further enclosed by a second material layer forming a connector interface with latch members, allowing for releasable coupling to a housing, providing enhanced protection and versatility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire connector assembly is replaced upon component failure, then reliability is maintained, but loss of time and manufacturing cost increase
Solution Approach 1:
The connector assembly is segmented into modular components: a reusable housing and replaceable connector elements (circuit board, terminal pins, electrical components). This allows only the failed connector elements to be replaced while retaining the housing, thereby reducing replacement time and cost while maintaining reliability.
2Reliability
If the entire connector assembly is replaced upon component failure, then reliability is maintained, but manufacturing cost increases
Solution Approach 1:
The connector assembly is segmented into modular components: a reusable housing and replaceable connector elements (circuit board, terminal pins, electrical components). This allows only the failed connector elements to be replaced while retaining the housing, thereby reducing replacement time and cost while maintaining reliability.
3Reliability
If the connector assembly is made fixed and permanent, then reliability is improved, but adaptability decreases
Solution Approach 1:
The connector assembly transitions from a fixed permanent connection to a dynamic releasable connection through latch members that can be engaged and disengaged. This allows the connector elements to be reliably connected during operation but easily separated for replacement or reconfiguration, providing both reliability and adaptability.
Solution Approach 2:
The connector assembly is segmented into modular components: a reusable housing and replaceable connector elements (circuit board, terminal pins, electrical components). This allows only the failed connector elements to be replaced while retaining the housing, thereby reducing replacement time and cost while maintaining reliability.
4Reliability
If protection structures are added to protect circuit board and components, then reliability is improved, but device complexity increases
Solution Approach 1:
The housing combines multiple functions into a single structure: it provides mechanical protection for the circuit board and electrical components, serves as the mounting structure for connector elements, and integrates the releasable coupling mechanism through latch members. This integration provides protection without proportionally increasing complexity.
Data Source
AI summary
Embodiments herein are directed an assembly. The assembly includes a circuit board, a plurality of terminal pins, a first material layer, and a second material layer. The circuit board includes a plurality of electrical components. The plurality of terminal pins extend from the circuit board. The first material layer encases a portion of the circuit board and the plurality of electrical components. The second material layer encloses the first material layer and the circuit board. The second material layer defines a connector interface portion that includes a plurality of latch members extending therefrom. A material of the second material layer different from a material of the first material layer.