Power Supply Device Connector Assembly for Reliable Circuit Board Connection
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Solution Overview
Problem
Existing power supply devices with multiple electricity storage elements face challenges in efficient and reliable connection to circuit boards due to complex and time-consuming lead wire connections, which can be affected by heat and require precise positioning, leading to reduced reliability and increased operational burden.
Innovation Solution
A power supply device configuration that includes a conductive connector and relay terminal connected to the circuit board before adding electricity storage elements, using a resin holder with fitting grooves for lead terminals, allowing for simplified connection and reduced stress on components, eliminating the need for precise positioning and minimizing exposure to heat and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lead wires are connected to the circuit board through reflow soldering, then electrical connection is achieved, but the electricity storage elements are affected by heat during the soldering process
Solution Approach 1:
The connection process is divided into two independent stages: first, the circuit board with relay terminals is soldered separately; second, the electricity storage elements with connectors are mounted and connected to the relay terminals. This segmentation allows the soldering heat to affect only the circuit board and relay terminals, protecting the electricity storage elements from thermal damage.
Solution Approach 2:
The relay terminals are pre-soldered to the circuit board before the electricity storage elements are mounted. This preliminary action completes the soldering operation while the board is accessible, avoiding subsequent disassembly and preventing heat exposure to the already-mounted electricity storage elements.
2Reliability
If multiple lead wires are individually connected through through holes, then electrical connection is achieved, but the connection process becomes time-consuming and labor-intensive
Solution Approach 1:
Multiple lead wire connections are merged into a single connector component. The connector integrates multiple connection points into one unit that can be mounted and connected to the circuit board in a single operation, dramatically reducing assembly time and labor while maintaining reliable electrical connections for all lead wires.
Solution Approach 2:
The connector serves multiple functions simultaneously: it provides mechanical support for multiple lead wires, establishes electrical connections for all connected terminals, and enables a single mounting operation to replace multiple individual connection steps. This multi-functionality resolves the contradiction between connection reliability and assembly efficiency.
3Reliability
If compliant pins are pressed into through holes for connection, then electrical connection is achieved, but precise positioning is required which increases operational burden
Solution Approach 1:
The connector acts as an intermediary component between the electricity storage elements and the circuit board. It provides a standardized interface with built-in positioning features that guide alignment, eliminating the need for precise manual positioning during assembly while ensuring reliable electrical connections through the intermediary connection points.
4Reliability
If lead wires are bent into L-shape and passed through through holes, then connection is achieved, but the number of operation steps increases
Solution Approach 1:
The complex lead wire bending and routing operations are extracted from the assembly process and replaced by pre-formed connectors. The connectors are manufactured separately with optimized connection geometries, eliminating the need for on-site lead wire manipulation and reducing the overall complexity of the assembly process while maintaining connection reliability.
Data Source
AI summary
A power supply device that includes a plurality of electricity storage elements each including lead terminals; a conductive connector connected to the lead terminals; a circuit board including a conductive path; a conductive relay terminal electrically connected to the conductive path, the connector being disposed so as to be in contact with the relay terminal; and a resin holder configured to hold the plurality of electricity storage elements, wherein the holder includes an electricity storage element holder configured to hold the electricity storage elements, a connecting member holder configured to hold the connector, and a fitting groove into which the lead terminals can be fitted, and the connecting member holder is formed so as to traverse the fitting groove.