Universal Power Input Assembly Using Segmented Circuit Boards
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Solution Overview
Problem
Existing power supply designs face challenges with thick, rigid 14 AWG wires connecting AC power sockets to motherboards, leading to assembly difficulties and overstressed solder joints due to space constraints and high power density, compromising safety and reliability.
Innovation Solution
A universal power input assembly featuring a first circuit board connected to an input power terminal and a second circuit board configured as a motherboard, using connectors to facilitate easy replacement of input power terminals without altering the motherboard, allowing for compact and reliable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a 14 AWG wire is used to connect the AC power socket to the motherboard, then the maximum AC input current can increase to 1.5 A, but the wire is relatively thick and unpliant, causing assembly difficulties and overstressed solder joints
Solution Approach 1:
The patent divides the connection system into three separate components: the input power terminal, the first circuit board, and the second circuit board (motherboard). This segmentation eliminates the need for thick, rigid 14 AWG wires by using standardized circuit board connectors that can accommodate high current (1.5 A) while maintaining flexibility and ease of assembly. The connector is integrated into the first circuit board, allowing the power terminal to be replaced without handling lengthy wires.
Solution Approach 2:
The first circuit board serves as an intermediary component between the input power terminal and the motherboard. It includes a connector that electrically couples the input power terminal to the motherboard, eliminating the need for direct wire connections. This intermediary structure provides a flexible, standardized interface that resolves the assembly difficulties associated with rigid 14 AWG wires while maintaining the required current-carrying capacity.
2Power
If a 14 AWG wire is used to connect the AC power socket to the motherboard, then the maximum AC input current can increase to 1.5 A, but the wire is applied with great stress after bending, reducing safety and reliability
Solution Approach 1:
By segmenting the connection system into discrete components (input power terminal, first circuit board with connector, second circuit board), the patent eliminates the stress concentration issues inherent in bent 14 AWG wires. The connector provides a rigid, stress-distributed connection path that maintains electrical integrity and mechanical strength under high current conditions, significantly improving safety and reliability.
Solution Approach 2:
The first circuit board with integrated connector acts as a mediator that provides a stable, stress-resistant connection between the power terminal and motherboard. This intermediary structure distributes mechanical and electrical stress across multiple connection points rather than concentrating it in a single bent wire, thereby enhancing the overall reliability and safety of the power input assembly.
3Power
If the space left for the power socket is relatively small for higher power density, then the 14 AWG wire is relatively thick and unpliant, but a flexible connection is needed for assembly
Solution Approach 1:
The patent segments the power connection system into compact, integrated components. The first circuit board with the connector is designed as a compact unit that fits within the limited space available for power sockets. This eliminates the need for lengthy, flexible wires by providing direct, rigid connections through the circuit board traces and connector, thereby maintaining high power density while achieving the required connection flexibility through modular assembly.
Solution Approach 2:
The connector is designed with a three-dimensional structure that optimizes space utilization. By routing connections through the thickness of the circuit board and using vertical mounting orientations, the design achieves compact footprint while maintaining adequate connection length and flexibility. This dimensional optimization allows high power density in the horizontal plane while providing sufficient connection freedom in the vertical dimension.
Data Source
AI summary
A universal power input assembly includes an input power terminal, a first circuit board and a second circuit board. The input power terminal is electrically coupled to the first circuit board and the first circuit board includes a connector, wherein a first end of the connector is electrically coupled to the first circuit board and a second end of the connector is electrically coupled to the second circuit board.