Plug Connector Circuit Carrier for Simplified Smart Assembly
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Solution Overview
Problem
Existing 'smart' plug connectors are complex to assemble due to the need for multiple components, including a printed circuit board and additional circuit components, which complicates the assembly process.
Innovation Solution
A one-piece carrier body made of non-metallic material, such as plastic, with integrated metal conductor tracks and a sensor device, is designed to simplify assembly by being inserted directly into the plug connector housing, eliminating the need for separate assembly of individual components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a printed circuit board with separate sensor device and control device is used, then the electrical circuit functions are achieved, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent combines the sensor device, control device, and printed circuit board into a single integrated circuit carrier. This merging eliminates the need for separate assembly of multiple components, directly resolving the contradiction between achieving electrical circuit functions and maintaining simple assembly processes.
Solution Approach 2:
The circuit carrier serves multiple functions simultaneously: it acts as the structural support, the electrical circuit board, and the mounting platform for sensor and control devices. This multi-functionality reduces the number of separate components needed, simplifying the overall assembly process while maintaining all necessary electrical functions.
2Adaptability or versatility
If multiple separate components (printed circuit board, sensor device, control device, contact cores, transformer coils) are used, then all necessary functions are achieved, but the number of parts increases and assembly becomes more difficult
Solution Approach 1:
The patent merges multiple separate components including contact cores, transformer coils, sensor devices, and control devices into a single integrated circuit carrier assembly. This consolidation maintains all necessary functional capabilities while dramatically reducing the number of discrete parts that need to be handled and assembled.
Solution Approach 2:
The patent segments the entire assembly into two main parts: the circuit carrier (containing all electronic components) and the housing. This segmentation allows the complex electronic components to be pre-assembled and tested as a single unit, then easily installed into the housing, simplifying the overall assembly process.
3Ease of manufacture
If a conventional plate-shaped printed circuit board is used, then the electrical circuit can be mounted, but the carrier body must accommodate additional components requiring separate assembly and covering
Solution Approach 1:
The patent merges the printed circuit board with the carrier body into a single integrated component. All electronic components are mounted directly on this integrated structure, eliminating the need for separate carrier bodies, additional mounting plates, and separate covers, thereby reducing the total number of parts while maintaining ease of circuit mounting.
Data Source
AI summary
An electrical plug connector (10) having contacts (30) on the input side and a housing (20), within which electrical lines (40) and an electrical switch with at least one sensor device (84) and a control device (82) are connected to the contacts (30). The sensor device (84) and the control device (82) are arranged on a common carrier body (70). The carrier body is formed as a circuit carrier, which is made from plastic by injection-molding, on which metallic conductor tracks (80) are applied. This allows simple integration of sensor and monitoring tasks into conventional plug connectors.