Curved PCB Connector Legs for Precise Low-Force Mounting
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Solution Overview
Problem
The complexity and high force requirements of press fit manufacturing processes for connecting devices to printed circuit boards (PCBs) make them time-consuming and labor-intensive, especially when compared to surface mount technology (SMT) processes.
Innovation Solution
A device with curved legs that deform to apply opposing forces on the PCB, allowing for precise connection with lower force requirements, utilizing a frame with integral legs that are curved in opposite directions to securely attach to the PCB without the need for high force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If press fit manufacturing process is used to connect devices to PCB, then high precision connection is achieved, but manufacturing complexity and time increase
Solution Approach 1:
The patent applies curvature to the legs of the device, transforming them from straight to curved shapes. This curvature enables the legs to deform elastically during insertion into the PCB holes, providing self-centering and compliant engagement that achieves high precision connection without requiring complex press fit manufacturing processes. The curved geometry allows the legs to flex and adapt to slight variations in hole positioning while maintaining accurate alignment.
2Manufacturing precision
If press fit manufacturing process is used to connect devices to PCB, then high precision connection is achieved, but manufacturing time and labor increase
Solution Approach 1:
The curved legs are designed to automatically self-center and self-adjust during insertion into the PCB holes. The elastic deformation of the curved legs provides inherent compliance that guides them into proper alignment without requiring external alignment mechanisms or complex manufacturing processes. This self-service capability enables simpler, faster manufacturing while maintaining high precision connection.
3Ease of manufacture
If curved legs are used to reduce force requirements, then ease of manufacture improves, but connection stability may be compromised
Solution Approach 1:
The curved legs transition from a static straight configuration to a dynamic curved configuration that can elastically deform during insertion and operation. This dynamic behavior allows the legs to flex and adapt to manufacturing tolerances and thermal expansions, providing both ease of insertion (reduced force requirements) and reliable stable connection through continuous elastic contact with the PCB hole walls.
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 high-precision connection of devices to PCBs in SMT manufacturing processes with reduced force and complexity, saving time and labor by using curved legs that apply spring-like forces for secure fixation.
Implementation Method 1
the first leg and the second leg deform such that a portion of the first leg contacts a respective portion of the first hole wall and a portion of the second leg contacts a respective portion of the second hole wall
Data Source
AI summary
A device may include a frame, a first leg extending from the frame, and a second leg extending from the frame, wherein each of the first leg and the second leg is curved in a respective direction, the respective directions being different.