Component Holding Structure for Vertical PCB Stacking
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Solution Overview
Problem
The existing methods for mounting multiple electronic components on printed circuit boards (PCBs) often result in wasted space and compromised mechanical integrity due to the need for hand-stacking and soldering, which increases assembly costs and requires secondary mechanical support.
Innovation Solution
A component holding structure with opposing end walls and lead guides is used to securely stack axial through-hole components vertically, allowing for efficient use of PCB space and eliminating the need for hand soldering and secondary support by facilitating a wave solder process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple components are hand stacked and soldered, then the components can be vertically arranged to reduce X-Y space usage, but the mechanical integrity of the assembly is compromised and secondary mechanical support is required
Solution Approach 1:
The holding structure is divided into multiple cavities, each capable of independently receiving and securing a through-hole component. Each cavity acts as a separate segmentation that provides individual mechanical support while contributing to the overall vertical stacking arrangement, thereby maintaining both space efficiency and mechanical integrity.
Solution Approach 2:
The holding structure serves as an intermediary component between the PCB and the stacked through-hole components. It provides the necessary mechanical support and positioning, eliminating the need for secondary mechanical support while enabling vertical arrangement to reduce PCB footprint.
2Area of stationary object
If multiple components are hand stacked and soldered, then vertical stacking is achieved, but assembly complexity and cost increase due to manual operations
Solution Approach 1:
The holding structure is pre-formed with multiple cavities and integrated support features before assembly. This preliminary preparation enables automated placement of multiple components in vertical stacks without requiring manual stacking and soldering operations, thereby reducing assembly complexity while maintaining space efficiency.
3Ease of manufacture
If traditional placement methods are used, then assembly process is simple, but significant planar PCB space is occupied
Solution Approach 1:
The holding structure enables transition from traditional planar (2D) component placement to vertical (3D) stacking arrangement. Multiple through-hole components are arranged vertically within cavities of the holding structure, significantly reducing the planar PCB footprint while maintaining ease of manufacture through automated assembly processes.
Data Source
AI summary
A component holding structure for holding a plurality of through-hole components having an axial lead includes a pair of opposing end walls that define a cavity between them. The cavity is configured to receive the through-hole components. The through-hole components are positioned between the pair of opposing end walls in a vertically-stacked configuration. Each one of the end walls includes at least one slot that is configured to receive the axial lead of each through-hole component when the plurality of through-hole components are inserted into the component holding structure. Each one of the end walls also includes a plurality of lead guides that are configured to guide the axial lead of each through-hole component when the plurality of through-hole components are inserted into the component holding structure.