Socketed PCB Magnetics for Reworkable Power Component Mounting

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Solution Overview

Problem

Direct soldering of power components to circuit boards results in heat damage, difficulty in replacement, and limited design flexibility due to space constraints.

Innovation Solution

A power component configured to be removably coupled to a printed circuit board assembly using a custom carrier body with support legs and pins, allowing for easy assembly and disassembly, and utilizing sockets and fasteners for secure attachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If power component is directly soldered to circuit board, then electrical connection is achieved, but heat damage to circuit board and difficulty in replacement occur

Engineering Contradiction:

Improveelectrical connectionVSAvoidheat damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a socket as an intermediary component between the power component and the circuit board. The socket is soldered to the board while the power component is removably coupled to the socket, thereby mediating the connection and eliminating direct soldering of the power component to the board. This resolves the heat damage issue while maintaining reliable electrical connection.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If power component is directly soldered to circuit board, then electrical connection is achieved, but replacement becomes difficult

Engineering Contradiction:

Improveelectrical connectionVSAvoidreplacement difficulty

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The patent segments the connection system into two separate parts: the socket that is permanently soldered to the circuit board, and the power component that is removably coupled to the socket. This segmentation allows the power component to be easily replaced by simply detaching it from the socket without affecting the board or requiring de-soldering operations.

Inventive Principle:

Principle #1Segmentation

3Strength

If power component is directly soldered to circuit board, then secure attachment is achieved, but space availability and design flexibility are limited

Engineering Contradiction:

Improveattachment securityVSAvoiddesign flexibility

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent transitions from a two-dimensional planar attachment (direct soldering on the board surface) to a three-dimensional configuration where the power component is elevated above the board via the socket. This dimensional change provides vertical space for component placement while maintaining secure attachment, thereby improving design flexibility and space utilization.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS12507345B2Re-workable socketed space saving magnetics

Publication Date: 2025.12.23 ROCKWELL COLLINS INC

AI summary

A system including a power component that is configured to be removably couplable to a printed circuit board (PCB) assembly is disclosed. The power component may include a power sub-component coupled to a plurality of wire leads and a carrier. The carrier may include a body defining a recess configured to receive the power sub-component and support legs extending from the body. The power component may be elevated above PCB components by virtue of the support legs. The system may also include pins configured to be coupled to the plurality of wire leads and inserted through the attachment features and into receiving features (e.g., sockets) of the printed circuit board assembly to electrically couple the plurality of wire leads to the receiving features of the printed circuit board assembly.