Carrier for Flexible Lead Electronic Devices
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Solution Overview
Problem
Conventional carriers are unsuitable for loading electronic devices with fine flexible leads, as they tend to deform or detach during manufacturing, leading to reduced efficiency and potential damage.
Innovation Solution
A carrier with a base, loading device, first pressing device, and second pressing device is designed to securely mount and electrically contact electronic devices, featuring a rotatable carrier pressing block, elastic components, and positioning structures to securely hold and attach lead ends, allowing for automatic loading and protection of flexible leads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional tray is used to load electronic devices with flexible leads, then the manufacturing process is simple, but the leads are easily pulled off or deformed
Solution Approach 1:
The carrier is divided into multiple functional modules: a base for positioning, a loading device for securing the electronic device, a first pressing device for contacting the circuit board, and a second pressing device for securing the lead end. Each module performs a specific function to protect the flexible leads while maintaining manageable complexity through modular design.
Solution Approach 2:
The carrier acts as an intermediary device between the electronic device and the manufacturing process. It provides a protective interface that secures the flexible leads during handling and manufacturing, preventing direct contact and potential damage from external forces.
2Productivity
If artificial manufacturing methods are used for electronic devices with flexible leads, then the leads are protected from damage, but manufacturing efficiency is reduced
Solution Approach 1:
The carrier is designed to automatically perform multiple functions: the loading device automatically secures the electronic device, the first pressing device automatically contacts the circuit board, and the second pressing device automatically secures the lead end. This self-service capability eliminates the need for complex artificial operations while maintaining lead protection.
Solution Approach 2:
The pressing devices incorporate elastic components that provide dynamic, adaptive pressure to the leads and circuit board. This dynamic mechanism automatically adjusts to the specific device being loaded, simplifying the handling process while ensuring consistent protection of the flexible leads.
3Reliability
If the electronic device is directly placed in a tray, then the loading process is fast, but the flexible leads are easily damaged
Solution Approach 1:
The carrier is pre-configured with positioning structures, pressing devices, and contact mechanisms before the electronic device is loaded. The loading device, first pressing device, and second pressing device are all prepared in advance to immediately secure and contact the device upon loading, eliminating the need for subsequent protective operations and maintaining fast loading times.
Solution Approach 2:
Multiple protective functions are merged into a single carrier structure: positioning the electronic device, contacting the circuit board, and securing the lead end are all combined in one integrated system. This merging allows all protective actions to occur simultaneously during the loading process, preventing lead damage without increasing loading time.
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
Enhances manufacturing efficiency and protects lead ends by securely loading and attaching electronic devices, preventing deformation and detachment, thus improving the handling of heat-sensitive sensors and similar devices.
Implementation Method 1
an elastic component mounted on the base and adapted to push the handle upward
Data Source
AI summary
A carrier includes a base on which a circuit board is mounted, a loading device mounted on the base, a first pressing device mounted on the base, and a second pressing device mounted on the base. The loading device is configured to load an electronic device on the base. The first pressing device is configured to press a first lead end protruding from the electronic device on the circuit board to electrically contact the circuit board. The second pressing device is configured to press a second lead end of the electronic device on the base.