Electric Connection Structure with Simultaneous Press-Fit and Welding
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Solution Overview
Problem
Conventional electric connection structures require multiple steps to connect an electric device and a circuit board using a connection terminal, increasing the complexity of the process.
Innovation Solution
An electric connection structure that uses a connection terminal with a press-welded terminal portion for the electric device and a press-fit terminal portion for the circuit board, allowing both connections to be made simultaneously through a single pressing step, utilizing a stress absorber to manage thermal expansion differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connection methods (crimping + soldering) are used to connect the connection terminal to both the electric device and circuit board, then reliable electrical connection is achieved, but the number of connection steps increases
Solution Approach 1:
The patent combines two separate connection operations (crimping to electric device and soldering to circuit board) into a single press-fitting operation. The connection terminal is designed with a press-fit structure that allows simultaneous connection to both the electric device terminal and circuit board through-hole in one step, eliminating the need for multiple sequential steps while maintaining connection reliability
Solution Approach 2:
The connection terminal is designed with a universal press-fit structure that can perform multiple connection functions simultaneously. The same press-fitting mechanism achieves both the mechanical/electrical connection to the electric device and the connection to the circuit board, making the connection terminal multi-functional and eliminating the need for different connection methods for different targets
2Productivity
If the connection terminal is pressed against the electric device terminal and into the circuit board through-hole simultaneously, then the number of connection steps is reduced, but different pressing directions are required
Solution Approach 1:
The connection terminal employs an asymmetric L-shaped structure where the first terminal portion and second terminal portion are oriented at different angles and extend in different directions. This asymmetric geometry allows the terminal to engage with the electric device terminal and circuit board through-hole at different orientations, enabling simultaneous connection through a single pressing action despite the different spatial requirements of the two connection targets
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 approach reduces the number of connection steps, enhances reliability by managing stress, and lowers manufacturing costs by maintaining a flat conductive plate configuration without the need for complex shaping.
Implementation Method 1
a press-welded terminal portion welded to a device terminal of the electric device by pressing
Implementation Method 2
a press-fit terminal portion fitted in a through-hole of the circuit board by pressing
Implementation Method 3
utilizing a stress absorber to manage thermal expansion differences
Data Source
AI summary
An electric connection structure electrically connecting an electric device and a circuit board includes a connection terminal including a press-welded terminal portion welded to a device terminal of the electric device by pressing, and a press-fit terminal portion fitted in a through-hole of the circuit board by pressing. A direction of the pressing of the press-welded terminal portion against the device terminal is the same as a direction of the pressing of the press-fit terminal portion into the through-hole.