Modular electrical interface
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Solution Overview
Problem
Conventional HVAC devices face challenges with solder connections, which complicate assembly, are prone to breakage, and can be easily damaged by external forces, leading to instability and reliability issues in fluid flow measurement and regulation systems.
Innovation Solution
A modular HVAC device with a solder-free electrical interface, featuring a connector with lead wires and a tension protection module, allowing for flexible design and secure mechanical load absorption, ensuring reliable power and signal supply to the PCB without the need for soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solder connections are used to connect lead wires to PCB, then electrical connection is established, but assembly becomes complicated and connections may break under external forces
Solution Approach 1:
The patent replaces the soldering process (thermal/mechanical bonding) with a mechanical connector system. The lead wires are terminated with connectors that mate with corresponding receptacles on the PCB, eliminating the need for soldering while providing reliable electrical connection and mechanical strength to resist external forces.
2Ease of operation
If conventional cable connections are used, then power and signals are supplied to the device, but the cable connection may be destroyed easily by application of external forces
Solution Approach 1:
The patent incorporates a cable gland or strain relief mechanism at the point where the cable enters the housing. This pre-positioned structural feature distributes and absorbs external mechanical stresses before they can reach the internal cable connections, preventing damage while maintaining simple cable installation.
3Reliability
If solder connections are used, then electrical connection is achieved, but the connections may break or be insufficient under certain conditions
Solution Approach 1:
The patent replaces the soldering process (thermal/mechanical bonding) with a mechanical connector system. The lead wires are terminated with connectors that mate with corresponding receptacles on the PCB, eliminating the need for soldering while providing reliable electrical connection and mechanical strength to resist external forces.
4Reliability
If a modular electrical interface with tension protection module is implemented, then mechanical loads are absorbed and reliability is enhanced, but device complexity increases
Solution Approach 1:
The patent divides the electrical interface into separate functional modules: the connector portion attached to lead wires, the receptacle on the PCB, and the tension protection module integrated with the housing. This segmentation allows each component to perform its specific function optimally while maintaining overall system reliability without excessive complexity.
Solution Approach 2:
The tension protection module serves multiple functions: it provides mechanical strain relief, anchors the cable assembly, and integrates with the housing structure. This multi-functionality reduces the need for separate components, thereby limiting the increase in overall device complexity while enhancing reliability.
Data Source
AI summary
A device for use in an HVAC application may have a housing including a housing body consisting of walls that determine an inner space of the housing. Connecting frames establish an edge of receiving slots for receiving standard solder-free connectors. At the outer face of the connecting frames connecting lugs are formed. Furthermore, the device has an electrical interface module. The electrical interface module includes a standard solder-free connector and a tension protection module. The standard solder-free connector may be connected directly to a printed circuit board and fixed by the tension protection module.