Compact Surge Protector with Threaded Housing and Spring Fixing
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Solution Overview
Problem
Existing surge protectors for small and micro base stations are too large and require frequent replacement when damaged, leading to high maintenance costs and space constraints due to their direct soldering on circuit boards, which can result in loosening and decreased performance or failure during surge shocks.
Innovation Solution
A compact surge protector design featuring stacked graphite sheets and insulation gaps within a round insulating housing, secured by insulating fixing clips and springs, with mounting electrodes and threaded housing for secure attachment, preventing loosening during surge events and facilitating high-density circuit board integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the surge protector is directly soldered to the circuit board to reduce size, then the volume is reduced, but the reliability decreases because the entire circuit board needs to be replaced when damaged
Solution Approach 1:
The surge protector is segmented into a modular design with a separate base that can be independently soldered to the circuit board. This allows the surge protector to be divided into replaceable components, maintaining small overall volume while improving reliability through selective replacement of only the damaged surge protector module rather than the entire circuit board.
2Device complexity
If the graphite sheets and insulation gaps are fixed using traditional methods, then the structure is simple, but the stability deteriorates because the structure loosens after surge shock
Solution Approach 1:
The fixing structure incorporates dynamic elements including springs that can compress and expand, and threaded connections that allow for adjustment and tightening. This dynamic design enables the fixing structure to absorb shock from surge events while maintaining stable fixation of the graphite sheets, preventing loosening without requiring overly complex rigid constraints.
3Volume of moving object
If the surge protector is designed with high-density component arrangement to meet miniaturization requirements, then the volume is reduced, but the ease of manufacture decreases
Solution Approach 1:
The surge protector employs a segmented modular architecture where the base unit with high-density components is separately manufactured and then assembled to the main body. This segmentation allows the high-density component arrangement to be produced using standardized manufacturing processes for the base module, while the overall assembly remains simple and maintainable, thus achieving miniaturization without excessively complicating manufacturing.
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 solution effectively prevents graphite sheets and insulation gaps from loosening during surge shocks, ensuring stable performance, reducing maintenance costs, and enabling miniaturization and integration of power supply circuits while allowing for easy installation and soldering.
Implementation Method 1
Two ends of the housing are provided with threads for matching with the fixing cap and being screwed tight... The forces of springs, which are provided on two sides of a stack of graphite sheets and insulation gaps thereof, act on the graphite sheets and insulation gaps thereof
Data Source
Figure 1~2
Figure 3
AI summary
The present invention discloses a structure for fixing graphite sheets and insulation gaps. The structure comprises housing, electrodes, springs and fixing caps, wherein the housing is configured to receive a stack of graphite sheets and insulation gaps stacked in combination, both ends of the housing are provided with threads; the fixing caps match with the housing and are to be screwed tight onto the housing; the electrodes are to be located at both ends of the stack of graphite sheets and insulation gaps; and the springs are to be located between the electrodes and the fixing caps.