Fork-Shaped Adapter for PCB Assembly Stress Absorption
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Mechanical stresses at electrical and mechanical connections in assemblies, such as those in high-current batteries or motor vehicle systems, can lead to damage due to tolerances, heating, and manufacturing parameters, causing structural instability and potential destruction.
Innovation Solution
An adapter part, specifically a fork-shaped element, is introduced between subassemblies to absorb forces, allowing for secure electrical and mechanical connections by being screwed, riveted, welded, or soldered to both components, thereby reducing mechanical stress and maintaining tolerance flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If subassemblies are directly connected without an adapter part, then the structure is simpler and manufacturing is easier, but mechanical stresses from tolerances and thermal expansion cause damage to the electrical and mechanical connections
Solution Approach 1:
An adapter part is introduced as an intermediary component between the first subassembly (printed circuit board) and the second subassembly (electromechanical component). This adapter absorbs mechanical stresses arising from tolerances and thermal expansion, protecting the electrical and mechanical connections from damage while maintaining connection reliability.
Solution Approach 2:
The connection system is segmented into three distinct parts: the first subassembly, the adapter part, and the second subassembly. This segmentation allows the adapter to specifically handle mechanical stress absorption while the other components maintain their primary functions, resolving the contradiction between reliability and complexity.
2Stability of the object's composition
If tolerances and tolerance positions are strictly controlled to reduce mechanical stresses, then connection stability improves, but manufacturing precision requirements increase and cost rises
Solution Approach 1:
The adapter part serves as a stress-absorbing intermediary that compensates for tolerance variations. By placing this compliant component between the subassemblies, the system maintains connection stability without requiring extremely tight manufacturing tolerances on the main components.
Solution Approach 2:
The adapter part is designed with specific material properties and geometric features (such as elastic materials or compliant structures) that allow it to deform and absorb stress. This changes the mechanical parameters of the connection system, enabling stability while accommodating broader tolerance ranges.
3Power
If high currents are conducted through the printed circuit board, then power transmission capability increases, but heat stresses increase and can lead to destruction of the assembly
Solution Approach 1:
The adapter part acts as a thermal and mechanical intermediary between the high-current printed circuit board and the electromechanical component. It helps dissipate and distribute heat stresses, preventing concentration of thermal loads that could lead to assembly destruction while maintaining high power transmission capability.
Data Source
AI summary
The invention relates to an electrical assembly having a printed circuit board and having a component. The component can be, in particular, an electromechanical component, such as an electrical switching contact, an electrical switch, a relay or the like. The component is electrically and/or mechanically connected to the printed circuit board. A fork-shaped element is arranged between the component and the printed circuit board for the purpose of electrically and/or mechanically connecting the component to the printed circuit board.