Extended PCB Terminal Layout for Low-Stress Power Tool Wiring
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Solution Overview
Problem
Handheld power tools face challenges with wires experiencing stress due to multiple turns and bends within limited space, complicating the manufacturing process.
Innovation Solution
Incorporating extended terminals on the printed circuit board that allow wires to connect with fewer bends and larger bend radii, using insulative housings to reduce stress and simplify assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires are routed within limited power tool housing space, then all electrical components can be connected, but wires experience stress due to multiple turns and bends
Solution Approach 1:
The terminal extends vertically away from the PCB surface into three-dimensional space, allowing wires to connect from above without requiring horizontal routing through the confined housing space. This vertical extension transforms a 2D PCB surface connection into a 3D spatial connection, reducing wire bends and stress while maintaining all electrical connections within the housing.
2Ease of manufacture
If terminals are located directly on the PCB, then electrical connections are made, but wires require multiple bends and experience increased stress
Solution Approach 1:
The terminal is segmented into distinct portions: a first end portion connected to the PCB, a middle portion extending away from the PCB, and a second end portion for wire connection. This segmentation allows the terminal to provide both PCB mounting and extended wire access, simplifying assembly while reducing wire stress through the extended configuration.
3Reliability
If the terminal extends away from the PCB, then wire bends are reduced and bend radius is increased, but the terminal structure becomes more complex
Solution Approach 1:
The extended terminal structure serves multiple functions simultaneously: it provides electrical connection to the PCB, extends into space to reduce wire bends, and the middle portion can be surrounded by insulative housing for additional protection. This multi-functionality justifies the increased structural complexity by delivering multiple benefits from a single component.
Data Source
AI summary
A power tool includes a printed circuit board (PCB). The PCB includes a terminal configured to electrically couple to a wire to electrically couple a first component of the power tool with a second component of the power tool. The terminal extends away from the PCB to allow the wire to connect to the terminal with a lower amount of wire bends and/or a greater amount of wire bend radius compared to the wire being connected to the terminal at a location on the PCB where the terminal is located. The terminal includes a first end portion connected to the PCB, a second end portion opposite the first end portion connected to the wire, and a middle portion extending between the first end portion and the second end portion. The middle portion may be surrounded by an insulative housing of a terminal clip that is attached to the PCB.