Power Adapter Socket Assembly Using Elastic Contacts for EMI Control
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Solution Overview
Problem
Conventional power conversion module assembly structures are not conducive to automated production due to manual wire welding and are prone to electrical interference from crossed wires, making them inefficient and susceptible to EMI/RFI.
Innovation Solution
A power adapter assembly structure utilizing elastic elements to connect the socket and circuit board, ensuring stable electrical connections and avoiding interference by maintaining safe electrical clearance and creepage distances, allowing for automated assembly and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual wire welding is used to connect socket and circuit board, then electrical connection can be achieved, but automated production cannot be realized and assembly complexity increases
Solution Approach 1:
The patent extracts the manual wire welding process from the assembly and replaces it with elastic elements that are pre-integrated into the socket structure. This eliminates the need for separate manual welding operations and enables automated assembly through simple insertion and elastic contact.
Solution Approach 2:
The elastic elements serve as intermediaries between the socket and circuit board, providing both mechanical connection and electrical conduction. These elements replace the complex wire welding process while maintaining reliable electrical connection through elastic contact.
2Object-affected harmful factors
If leading wires are used to connect socket and circuit board, then electrical connection is achieved, but EMI/RFI interference occurs due to wire crossing
Solution Approach 1:
The patent removes the external leading wires from the system and replaces them with integrated elastic elements that are part of the socket structure. This eliminates wire crossing and the associated EMI/RFI interference while maintaining electrical connection through the elastic contact mechanism.
3Productivity
If manual assembly of socket and circuit board is performed, then precise connection can be achieved, but production efficiency decreases
Solution Approach 1:
The patent segments the connection function into separate elastic elements that can be independently positioned and assembled. This modular approach allows for precise positioning during automated assembly while maintaining manufacturing precision through the elastic contact mechanism that self-adjusts to ensure proper connection.
4Reliability
If wire length and direction are not controlled, then assembly is simpler, but electrical interference increases and connection reliability decreases
Solution Approach 1:
Instead of controlling wire length and direction through complex routing, the patent inverts the approach by using rigid elastic elements with fixed geometries that inherently maintain proper spacing and orientation. The elastic elements' structured design ensures reliable connection without requiring complex control of connection path.
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
The use of elastic elements simplifies the assembly process, reduces production costs, and enhances product competitiveness by eliminating EMI/RFI issues while enabling automated production and ensuring structural strength in electrical connections.
Implementation Method 1
the hanging arm of the elastic element is pressed to constantly abut the corresponding abutting surface by the elastic force generated during assembling the socket and the circuit board
Data Source
AI summary
A power adapter assembly structure is disclosed and includes a circuit board, a socket and at least one elastic element. The socket is disposed adjacent to the circuit board. The circuit board and the socket are configured to collaboratively form at least one abutting surface and at least one fixing surface. The elastic element is connected between the circuit board and the socket, and includes a main body, a fixed portion and a hanging arm. The fixed portion and the hanging arm are disposed at two opposite ends of the main body, the fixed portion spatially corresponds to the fixing surface, and the hanging arm constantly abuts the abutting surface. A height is formed between the main body of the at least one elastic element and the at least one abutting surface, and less than a length of the hanging arm extended from the main body.