Power Connector Structure to Reduce EMI and Solder Joint Failure
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Solution Overview
Problem
Conventional power adapters require significant space for routing live and neutral wire cables, leading to electromagnetic interference and potential solder joint failure due to repeated insertion and removal of the power cord.
Innovation Solution
A power connector design featuring a conductive pin and conductive elastic component that penetrates through the elastic component to establish an electrical connection with the circuit board, eliminating the need for separate wire routing and reducing electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate wire routing is used for live and neutral connections, then electrical connection is achieved, but space requirements increase and electromagnetic interference occurs
Solution Approach 1:
The patent combines the live wire and neutral wire routing paths into a single integrated wire routing structure. The wire routing channel is designed to accommodate both conductors together, reducing the total space required compared to separate routing paths. This merging approach maintains proper electrical isolation between conductors while minimizing the overall area occupied in the power adapter's internal layout.
Solution Approach 2:
The patent implements nested wire routing where the neutral wire is positioned within or alongside the live wire routing path. The wire routing channel is structured to contain both conductors in a compact arrangement, with the neutral wire effectively nested within the same routing corridor as the live wire, thereby reducing the lateral space required for wire management.
2Reliability
If separate wire routing is used for live and neutral connections, then electrical connection is achieved, but electromagnetic interference occurs
Solution Approach 1:
The patent combines the live wire and neutral wire routing paths into a single integrated wire routing structure. The wire routing channel is designed to accommodate both conductors together, reducing the total space required compared to separate routing paths. This merging approach maintains proper electrical isolation between conductors while minimizing the overall area occupied in the power adapter's internal layout.
Solution Approach 2:
The patent introduces an insulated barrier or shielding structure as an intermediary between the live wire and neutral wire within the wire routing channel. This intermediary element acts as a physical and electromagnetic separator, reducing coupling between the conductors and minimizing electromagnetic interference while still allowing both wires to pass through the same routing path.
3Reliability
If conductive elastic pieces are directly inserted and soldered onto the circuit board, then electrical connection is established, but solder joint cracks occur due to repeated insertion and removal
Solution Approach 1:
The patent extracts the solder joint from the connection path between the power connector and circuit board. Instead of directly soldering the conductive elastic piece to the circuit board, the invention introduces an intermediate connection mechanism (such as a press-fit terminal or mechanical connector) that eliminates the need for soldering at the point subject to mechanical stress from repeated plugging and unplugging.
Solution Approach 2:
The patent segments the electrical connection path into distinct functional sections: the conductive elastic piece for flexible contact, an intermediate mechanical connector for stable mounting, and the circuit board connection point. This segmentation allows each component to perform its optimal function while isolating the solder joint from mechanical stress caused by repeated connector insertion and removal.
4Ease of manufacture
If sufficient space is allocated for wire routing, then cable management is improved, but device volume increases
Solution Approach 1:
The patent implements nested wire routing where the neutral wire is positioned within or alongside the live wire routing path. The wire routing channel is structured to contain both conductors in a compact arrangement, with the neutral wire effectively nested within the same routing corridor as the live wire, thereby reducing the lateral space required for wire management.
Solution Approach 2:
The patent utilizes three-dimensional wire routing channels that allow wires to route in multiple dimensions rather than requiring large planar space. The wire routing structure incorporates vertical and lateral pathways that enable compact cable management within a small volume, transforming the wire routing problem from a two-dimensional layout issue into a three-dimensional spatial optimization.
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 design minimizes space requirements, reduces electromagnetic interference, and prevents solder joint failure, enhancing product reliability and stability.
Implementation Method 1
The conductive elastic component is electrically connected between the circuit board and the conductive pin
Implementation Method 2
The conductive elastic component is electrically connected between the circuit board and the conductive pin
Data Source
AI summary
A power connector is provided in the present invention. The power connector is adapted to be connected with a circuit board of a power adaptor. The power connector comprises a base, a conductive pin and a conductive elastic component. The conductive pin is disposed in the base. The conductive elastic component is electrically connected between the circuit board and the conductive pin. The conductive pin penetrates through the conductive elastic component.