Compliant Contact Terminal Structure for Low-Force PCB Insertion
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Solution Overview
Problem
Existing contact terminals require significant insertion force and cause deformation, preventing repeated use without tooling and headers.
Innovation Solution
A low insertion force contact terminal with a compliant portion featuring independently moving curved sections and optional embossments, allowing for stable electrical connections with minimal force and reduced deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If traditional contact terminals are used, then electrical connection is achieved, but insertion force is significant and causes deformation
Solution Approach 1:
The contact terminal is divided into multiple curved portions (first curved portion, second curved portion, third curved portion) that can move independently. This segmentation allows each portion to deform separately during insertion, distributing the insertion force and reducing peak stresses that would cause permanent deformation and failure after repeated use.
Solution Approach 2:
The contact terminal employs dynamic curved portions that can flex and deform during the insertion process rather than being rigid. The first, second, and third curved portions are designed to move and adapt during insertion, absorbing insertion forces elastically and returning to their original positions, enabling repeated use without permanent deformation.
2Ease of operation
If traditional contact terminals are used, then electrical connection is established, but tooling and headers are required for insertion
Solution Approach 1:
The contact terminal is designed to insert itself into the substrate through its own compliant curved portions that automatically deform and flex during insertion. The terminal does not require external tools or headers to facilitate insertion, as the curved portions self-adjust to guide and push the terminal through the substrate hole, simplifying the assembly process.
3Reliability
If normal force is increased for stable connection, then electrical connection stability improves, but insertion force increases
Solution Approach 1:
The contact terminal is divided into multiple curved portions (first, second, and third curved portions) that can move independently. This segmentation allows the terminal to achieve stable connection through distributed contact forces while maintaining low insertion force, as each curved portion contributes to both connection stability and force distribution during insertion.
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
Enables multiple cycles of connection without tooling, maintaining stability and reducing substrate deformation.
Implementation Method 1
The curved portions of the at least two sections move independently, which allows the curved portions to exert a low normal force on walls of through holes of a substrate to which the contact terminal is mated
Implementation Method 2
the at least one embossment on the first section or the second section increases the frictional engagement between the first section and the second section, thereby increasing the normal force that the curved portions exert on the wall of the through holes
Data Source
AI summary
A low insertion force contact terminal which has a conductor mating portion, a securing portion and a substrate mating portion. The conductor mating portion is configured to terminate a conductor therein. The securing portion is configured to secure the terminal in a terminal receiving cavity of a housing. The substrate mating portion extends from the securing portion. The substrate mating portion has at least two sections which have curved portions thereon. At least one embossment is provided on a first section of the at least two sections or a second section of the at least two sections. The curved portions of the at least two sections move independently, which allows the curved portions to exert a low normal force on walls of through holes of a substrate to which the contact terminal is mated. The low normal force is sufficient to provide a stable electrical connection.