Capacitor Relay Terminal Pressure Contact Assembly
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Solution Overview
Problem
The existing capacitor module designs require time-consuming and labor-intensive soldering operations to connect lead wires to the conductive path of a circuit board, which can expose capacitors to heat during reflow soldering, complicating the assembly process.
Innovation Solution
A power supply device with relay terminals and pressure contacts that simplify the electrical connection of capacitors to the circuit board, using a resin holder to manage the relay terminals and reduce the number of connections needed, and a cover with viewing holes to monitor the connection state, allowing for easier assembly and heat protection during soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If lead terminals are separately connected to the conductive path of the circuit board, then electrical connection is achieved, but the number of connections increases and assembly time increases
Solution Approach 1:
Multiple lead terminals having the same potential are merged into a single connection point through the relay terminal. The relay terminal consolidates multiple electrical connections into one board connector connection, reducing the number of soldering operations required while maintaining proper electrical connectivity for all connected capacitors.
Solution Approach 2:
The relay terminal acts as an intermediary component between the capacitors and the circuit board. It provides pressure contact connections to multiple capacitors and a single board connector connection to the circuit board, simplifying the assembly process by reducing the number of direct soldering operations needed.
2Ease of manufacture
If capacitors are connected during reflow soldering, then electrical connection is achieved, but capacitors are exposed to heat that may damage them
Solution Approach 1:
The relay terminal is soldered to the circuit board before the capacitors are connected to it. This preliminary connection allows the board connector to be firmly attached to the circuit board through reflow soldering, and then the capacitors are subsequently connected to the relay terminal without being exposed to the high temperatures of the reflow soldering process.
3Reliability
If multiple board connectors are used to connect each lead terminal, then electrical connection reliability is improved, but assembly complexity and time increase
Solution Approach 1:
Multiple board connector connections are merged into a single board connector connection. The relay terminal consolidates multiple electrical connections into one connection point on the circuit board, reducing the number of soldering operations required while maintaining proper electrical connectivity for all connected capacitors.
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 configuration simplifies the connection process, reduces the number of connections required, and protects capacitors from heat damage during reflow soldering, enhancing assembly efficiency and reliability.
Implementation Method 1
a relay terminal connecting the lead terminals to a conductive path of the circuit board, the relay terminal including a plurality of pressure contacts configured to come into pressure contact with a plurality of lead terminals
Data Source
AI summary
A power supply device that includes a plurality of capacitors including a plurality of lead terminals; a circuit board including a conductive path; a relay terminal configured to connect the lead terminals to the conductive path of the circuit board; and a cover configured to cover the plurality of lead terminals of the plurality of capacitors, wherein the plurality of capacitors are oriented such that the respective lead terminals are disposed on an inner side, and the relay terminal includes a plurality of pressure contacts configured to come into pressure contact with a plurality of lead terminals of the plurality of capacitors, the lead terminals having the same potential, and a board connector configured to be connected to the conductive path of the circuit board, a number of the board connector being smaller than a number of the plurality of pressure contacts.