Poke-in Contact Mount Assembly for Tool-Free PCB Connection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current systems for securing electronics in junction boxes either damage components due to lack of support during wire tabbing insertion or require tools for connection, leading to high costs and complexity in assembly and maintenance.
Innovation Solution
A poke-in contact mount assembly with a flexible, yet sturdy, locking lance that absorbs insertion forces, allowing tool-free connection and easy replacement, constructed from materials like copper or copper alloys, which provides secure retention without the need for additional support or tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a second capsule is added around the contact body to provide support, then the strength to withstand insertion force is improved, but the manufacturing cost and assembly time increase
Solution Approach 1:
The patent merges the support function into the base structure itself, eliminating the need for a separate second capsule. The base is designed with integrated support features that provide the necessary strength during wire tabbing insertion while maintaining a simpler manufacturing process and reducing assembly steps.
Solution Approach 2:
The base structure is designed to perform multiple functions: it provides mechanical support, anchors the contact, and withstands insertion forces. This multi-functional design eliminates the need for separate support components while maintaining structural integrity.
2Strength
If the junction box is constructed of strong material to withstand insertion force, then the strength is improved, but tools or equipment are required to initiate connection which increases time and cost
Solution Approach 1:
The contact features a movable lance that can deflect during wire tabbing insertion. This dynamic design allows the contact to absorb insertion forces through controlled movement rather than requiring rigid tool assistance, enabling tool-free connection while maintaining structural strength.
Solution Approach 2:
The patent changes the physical state and properties of the contact materials, using flexible yet sturdy materials that can deform elastically during insertion. This parameter change allows the contact to withstand forces without requiring tools, as the material properties enable controlled deformation and recovery.
3Strength
If tool connections are used to make permanent connections, then the connection strength is improved, but the ability to replace components is reduced
Solution Approach 1:
The patent segments the connection system into a permanent base structure and a replaceable contact component. The base remains fixed and provides structural strength, while the contact with its movable lance can be independently replaced without affecting the base or requiring tool-assisted permanent connections.
Solution Approach 2:
The design allows the contact component to be discarded and replaced when worn or damaged, while the base structure is recovered and reused. This enables easy maintenance and repair without replacing the entire assembly, reducing waste and maintenance costs.
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 solution reduces manufacturing, replacement, and maintenance costs while enabling easy repairs and replacements with minimal modifications, applying low normal forces during insertion and ensuring secure locking without tool assistance.
Implementation Method 1
a flexible, yet sturdy, locking lance that absorbs insertion forces
Implementation Method 2
constructed from materials like copper or copper alloys, which provides secure retention
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2
AI summary
A poke-in contact modular assembly (10) for a printed circuit board (12) that has a solderless connection with a junction box. The assembly allows for easier and more efficient removal and replacement of the printed circuit board and electrical components. In addition, the poke-in contact is configured to reduce the amount of normal force applied to the printed circuit board when wire tabbing is inserted into the contacts.