Twist-Lock Connector PCB Flexible Contacts
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Solution Overview
Problem
Traditional twist-lock connectors face issues such as inconsistent contact pressure, corrosion, and mechanical stress, leading to intermittent connections and safety hazards, while being costly and difficult to manufacture and install.
Innovation Solution
The design eliminates stamped and formed contacts by using plated contacts on a printed circuit board (PCB) or soldering solid metal contacts directly to the PCB, with flexible portions on the PCB that deform to secure male electrical contacts, reducing manufacturing costs and improving assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If stamped and formed contacts are used in traditional twist-lock connectors, then the connector structure is simple to manufacture, but the contact pressure varies greatly leading to intermittent electrical connection and connection failure
Solution Approach 1:
The patent replaces the traditional mechanical stamping and forming process with PCB-based electrical contacts that use standardized PCB fabrication techniques. This substitution eliminates the variability inherent in stamped contacts while leveraging the precision and automation of PCB manufacturing processes, thereby improving contact pressure consistency without significantly increasing manufacturing complexity
Solution Approach 2:
The patent changes the material and structural parameters of the electrical contacts by transitioning from stamped metal contacts to PCB-trace-based contacts with controlled impedance and consistent thickness. This parameter change enables uniform contact pressure across all contacts while maintaining ease of manufacture through standardized PCB production methods
2Reliability
If crimping is used to attach wires to stamped contacts, then the assembly process is simple, but the crimping may be incomplete or damage the wire causing connection failure
Solution Approach 1:
The patent extracts and eliminates the crimping step from the manufacturing process by using PCB-mounted electrical contacts that are directly soldered to the PCB. This removal of the crimping operation eliminates the associated reliability issues while the soldering process provides more consistent and reliable electrical connections
Solution Approach 2:
The patent introduces the PCB as an intermediary component that provides a stable, precision-machined mounting platform for electrical contacts. This intermediary eliminates the need for direct wire-to-contact crimping by providing a controlled environment for soldering, thereby improving connection reliability
3Ease of manufacture
If traditional twist-lock connectors are manufactured with multiple steps of stamping, forming, crimping, and terminating, then the connector can be made, but the manufacturing cost is high and the process is complex
Solution Approach 1:
The patent merges multiple discrete manufacturing steps (stamping, forming, crimping, terminating) into a single integrated PCB fabrication and assembly process. This consolidation reduces manufacturing complexity and cost while the automated PCB processes maintain or improve tolerance control through consistent, repeatable operations
Solution Approach 2:
The PCB serves multiple functions simultaneously: it provides structural support, electrical connection pathways, mounting for electrical contacts, and a platform for soldering. This multi-functionality eliminates the need for separate components and assembly steps, reducing overall manufacturing complexity and cost
4Object-affected harmful factors
If wires are used in traditional twist-lock connectors, then electrical connection can be established, but the wires may become disconnected and move to make electrical connection with the conductive housing presenting an electrical shock hazard
Solution Approach 1:
The patent extracts and eliminates the exposed wire portion from the connector design by using PCB-trace-based electrical connections. This removal of exposed wires eliminates the safety hazard of wires becoming disconnected and contacting conductive housing, while the enclosed PCB traces provide stable, protected electrical connections
Solution Approach 2:
The PCB acts as an intermediary that encloses and protects the electrical connection pathways. Instead of exposed wires that can move and create hazards, the PCB provides a rigid, enclosed structure that prevents wire displacement and eliminates electrical shock hazards while maintaining reliable connections
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
This solution provides reliable, consistent electrical connections with improved safety and reduced manufacturing costs, as the PCB's precise tolerances and automatic assembly processes enhance the twist-lock connector's performance and ease of installation.
Implementation Method 1
each of the flexible portions resiliently deform responsive to one of the male electrical contacts contacting and exerting a force on the electrical connectors positioned on the flexible portion to provide a biasing force
Data Source
AI summary
A twist-lock connector that includes a printed circuit board component with one or more flexible portions is disclosed. The flexible portions may be formed within an interior portion of the printed circuit board by routing or otherwise removing a portion of the printed circuit board to create one or a plurality of side for each flexible portion. One or more electrical contacts may be positioned on each flexible portion and arranged to be electrically coupled with male electrical contacts that are part of a corresponding twist-lock plug, thereby deflecting the flexible portions. When deflected, the flexible portions exert an opposing, biasing force in the direction of the male electrical contacts to maintain contact there between. One or more of a mounting base and a support base may be clamped to either or both sides of the printed circuit board to provide further stability for the flexible portions.