Universal PCB Power Board Using Bridge Sheets for Regional Plugs
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Solution Overview
Problem
Existing wireless communication devices require customized printed circuit boards for different geographical regions due to varying plug configurations, leading to increased costs and reduced economies of scale.
Innovation Solution
A wireless communication device design that uses a common printed circuit board layout with conductive pin structures and sheet metal connectors to accommodate different regional plug configurations, maintaining a consistent distance between neutral and live power inputs, allowing a single board design to be used across multiple regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If customized printed circuit boards are used for different geographical regions, then electrical connectivity for specific plug configurations is improved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent applies universality by designing a single printed circuit board that can accommodate multiple plug configurations through interchangeable bridge sheet metal components. The common power board layout with neutral and live power inputs remains the same, while different bridge sheets (e.g., first bridge sheet for North American plugs, second bridge sheet for European plugs) are used to adapt to various regional standards. This eliminates the need for customized PCBs for each region, reducing manufacturing complexity while maintaining reliable electrical connectivity.
2Adaptability or versatility
If customized printed circuit boards are used for different geographical regions, then plug configuration compatibility is improved, but economies of scale are reduced
Solution Approach 1:
The patent segments the plug adaptation function into separate interchangeable bridge sheet metal components rather than customizing the entire printed circuit board. The common power board remains standardized for mass production, while only the small bridge sheets need to be varied for different regions. This segmentation allows the majority of the device to benefit from economies of scale through standardized manufacturing, while still achieving plug configuration compatibility through the interchangeable bridge components.
Solution Approach 2:
The common printed circuit board design serves multiple functions across different geographical regions by supporting various bridge sheet configurations. A single PCB layout with neutral and live power inputs can work with North American, European, and other plug types by simply changing the bridge sheet, enabling universal compatibility while maintaining manufacturing efficiency through standardized board production.
3Adaptability or versatility
If multiple printed circuit board designs are used for different regions, then regional plug standards are accommodated, but manufacturing costs increase
Solution Approach 1:
The patent introduces bridge sheet metal components as intermediary elements between the common printed circuit board and various regional plug configurations. These bridge sheets act as mediators that adapt the standardized PCB to different plug standards (North American, European, etc.) without requiring customization of the PCB itself. This intermediary approach allows regional adaptation while maintaining standardized, cost-effective PCB manufacturing.
Data Source
AI summary
Wireless communication devices may include a printed circuit board and a conductive pin structure. The printed circuit board may include a neutral power input and a live power input positioned at a first distance from each other. The conductive pin structure may include a neutral pin and a live pin positioned at a second, different distance from each other. A first sheet metal connector may electrically connect the neutral pin to the neutral power input and a second sheet metal connector may electrically connect the live pin to the live power input. Various other related devices, components, systems, and methods are also disclosed.