Flange-Shaped Contacting Element for Simplified PCB Assembly
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Solution Overview
Problem
Existing methods for electrical connections between components, such as electronics and electric motors, are complex and require multiple steps like soldering, welding, or crimping, which can be costly and time-consuming, and often necessitate additional components like weldable carriers.
Innovation Solution
A contacting element with a flange-shaped design that allows for easy mechanical and electrical connection to a carrier device, enabling a simplified two-stage process involving soldering or crimping, and featuring a claw element for insulation removal and strain relief, reducing the need for additional steps and components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connection methods (soldering, welding, crimping) are used between electronics and electric motors, then reliable electrical connections are achieved, but the process becomes complex and time-consuming with multiple steps and additional components
Solution Approach 1:
The patent combines multiple connection functions into a single integrated contacting element. The element merges the electrical contact function with the mechanical support function (flange-shaped section for mounting to PCB) and the wire securing function (sleeve for crimping) into one component, eliminating the need for separate weldable carriers and reducing assembly steps while maintaining reliable electrical connections
Solution Approach 2:
The contacting element is designed as a multi-functional component that can be mounted to a PCB via its flange-shaped section, provide electrical contact through its conductive body, and secure a conductor wire through its sleeve section. This universal design allows a single component to replace multiple traditional connection elements and processes
2Reliability
If multiple connection steps (soldering, welding, crimping) are performed, then secure electrical connections are established, but production time and costs increase
Solution Approach 1:
The contacting element is pre-assembled with the flange-shaped section already integrated with the conductive body and sleeve, allowing it to be mounted to the PCB in a single soldering operation. The wire can then be inserted and crimped in one subsequent step, eliminating the need for separate preparation steps and reducing overall production time while maintaining connection security
3Reliability
If additional components like weldable carriers are used, then electrical connections between conductor wires and PCB are achieved, but space and costs increase
Solution Approach 1:
The patent extracts and eliminates the need for separate weldable carrier components by integrating all necessary functions into the single contacting element. The flange-shaped section directly provides the mounting interface to the PCB, removing the requirement for additional carrier components and reducing both part count and assembly complexity
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 solution simplifies the electrical connection process, reduces production steps, eliminates the need for welding and stripping, and saves space and costs by allowing cost-effective connections directly to printed circuit boards, including components like electrolytic capacitors.
Implementation Method 1
the contacting element can be soldered to the carrier device in a soldering process
Implementation Method 2
the actual electrical contacting process of the conductor wire with the contacting element
Data Source
Figure 1~3
Figure 4~6
AI summary
The invention relates to a contacting element (10) comprising a sleeve-shaped first section (10a) for establishing electric contact with an electric conducting wire (20), and at least one second section (10b) for establishing electric contact with and for mechanically fixing to the support device (40) for at least one electric conductor path (41).