Vertical PCB Connector Assembly for Electric Vehicle
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Solution Overview
Problem
Existing electric devices for electric vehicles face challenges in minimizing volume, weight, and assembly complexity due to the limited space availability and increased risk of malfunction from vibrations, especially when using two-layered printed circuit boards (PCBs) with protruding coupling parts and connectors.
Innovation Solution
The electric device features a lower and upper case with vertically disposed connectors on each PCB, allowing direct board-to-board connection without separate wires, enhancing space efficiency and assembly simplicity by using bolt or hook coupling for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If protruding upper PCB coupling parts are provided on the lower case to couple the upper PCB, then the upper PCB can be securely attached, but the lower PCB area is reduced and space is limited
Solution Approach 1:
The patent transitions from horizontal PCB arrangement to vertical stacking arrangement. The lower PCB and upper PCB are positioned at different vertical levels, with the upper PCB mounted on the inner surface of the upper case. This dimensional change eliminates the need for protruding coupling parts on the lower case, as the connectors interface vertically through corresponding holes in both PCBs, thereby preserving the full area of the lower PCB while maintaining secure attachment of the upper PCB.
2Reliability
If wires are used to connect the lower PCB to the upper PCB, then electrical connection can be established, but the upper space of the lower PCB is limited and assembly complexity increases
Solution Approach 1:
The patent merges the mechanical mounting function and the electrical connection function into a single integrated structure. The lower PCB and upper PCB are directly connected through their respective connectors that interface through corresponding holes, eliminating the need for separate wire connections. This consolidation reduces the number of assembly steps, removes wire management complexity, and maintains reliable electrical connection between the two PCBs.
3Reliability
If separate connectors and wires are used to connect PCBs, then electrical connection can be established, but the connector may separate during vibrations causing malfunction
Solution Approach 1:
The patent combines the mechanical mounting structure with the electrical connection structure. The connectors on the lower PCB and upper PCB are positioned to interface directly through corresponding holes in both PCBs, creating a rigid, integrated connection. This unified structure eliminates the use of separate wire connections and loose connectors, thereby preventing connector separation during vibrations and improving reliability in vibrational environments such as electric vehicles.
4Ease of manufacture
If multiple upper PCB coupling parts are provided on the lower case, then the upper PCB can be coupled to the lower case, but the assembly process number and manufacturing costs increase
Solution Approach 1:
The patent simplifies the coupling mechanism by transitioning from a complex multi-part coupling structure on the lower case to a direct vertical interface between PCBs. The upper PCB is mounted on the inner surface of the upper case with connectors that interface through corresponding holes in both PCBs, eliminating the need for multiple protruding coupling parts on the lower case. This reduces the number of components and assembly steps while maintaining the coupling capability.
Data Source
AI summary
An electric device for an electric vehicle is provided. The electric device includes a lower case, an upper case coupled to an upper portion of the lower case, a first printed circuit board (PCB) fixed to the lower case and comprising a first connector, and a second PCB fixed to the upper case and comprising a second connector. The first connector and the second connector are vertically disposed to correspond to each other, and the first connector is coupled to the second connector by coupling the lower case to the upper case to connect the first PCB to the second PCB.