Indicator Device with Integrated Clamp Screw for PCB Assembly
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Solution Overview
Problem
Existing electric indicating devices require manual assembly and connection, leading to increased manufacturing times and costs, risk of part loss during handling, and potential damage to the printed circuit board due to excessive torque, especially in complex or hard-to-reach installations.
Innovation Solution
An indicator device with a flat, sheet-like printed circuit board mounted perpendicularly to the casing, featuring self-tapping screws and pressure elements that apply controlled stress, allowing for automatic assembly and easy connection to system terminals without manual intervention, and designed for secure attachment to panels with quick-connect mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If clamping screw and nut are used to establish electric contact with printed circuit board pads, then electric connection is achieved, but the printed circuit board is under considerable pressure that may cause insulating medium breakdown
Solution Approach 1:
The patent introduces a clamp body as an intermediary component that distributes the clamping force across a larger area of the printed circuit board. Instead of concentrating pressure at a single screw-nut contact point, the clamp body spreads the load, preventing insulating medium breakdown while maintaining reliable electric connection through the pads.
Solution Approach 2:
The clamping mechanism is segmented into distinct functional parts: the clamp body for distributing pressure, the clamping screw for applying force, and the electric pads for contact. This segmentation allows each component to perform its specific function optimally, with the clamp body specifically designed to manage pressure distribution on the printed circuit board.
2Reliability
If clamping screw and nut are used as individual parts, then electric connection can be established, but manual positioning and tightening increases manufacturing time
Solution Approach 1:
The patent merges the clamp body with the clamping screw into a single integrated component. The clamp body is formed as one piece with the screw, eliminating the need for separate nut and clamp parts. This integration allows the entire clamping and connection mechanism to be installed in a single operation, dramatically reducing manual assembly time while maintaining reliable electric connection.
Solution Approach 2:
The integrated clamp screw design performs multiple functions simultaneously: it provides the clamping force, establishes electric contact through the pads, and secures the printed circuit board in place. This self-service capability eliminates the need for separate positioning and tightening steps, enabling faster manufacturing.
3Ease of operation
If screw is loosened and tightened again, then connection can be re-established, but alignment of screw shank with nut hole becomes complex in narrow spaces
Solution Approach 1:
By integrating the clamp body with the screw into a single component, the patent eliminates the separate nut that would require alignment. The integrated design allows the screw to be inserted and tightened in a single motion without needing to align with a separate nut hole, greatly simplifying reconnection operations in narrow or difficult-to-reach spaces.
4Ease of operation
If nut is separated from printed circuit board during handling, then part may be lost, but connection can still be made
Solution Approach 1:
The patent merges the clamp body with the screw into an integrated component that cannot be separated or lost during handling. This single-piece construction eliminates the risk of the nut separating and being lost, while still allowing the entire assembly to be easily installed and removed as needed for connection work.
Data Source
Figure 1~2
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Figure 5~6
AI summary
An indicator device adapted to be connected to a pair of terminals (E) of an electric system (I) and comprising a casing (2) adapted to be connected to a panel (P) of a machine and/or a push-button box and defining a longitudinal axis (L), an electronic board (3) held within the casing (2), and having an electronic circuit (7) and a bottom face (5) with a pair of conductive pads (8) formed thereon, at least one light source (9) installed on the board (3) and having a pair of contacts (10) electrically connected to the pair of pads (8), connection means (13) for electrically connecting the pads (8) directly with the terminals (E) of the system (I). The casing (2) is made of a first insulating base material and the board (3) is made of a second insulating base material having a maximum compression strength (Cmax) of predetermined value. The casing (2) comprises a body (14) which is adapted to be secured to the panel (P) and a bottom member (15) with a pair of seats (16) for the connection means (13), the latter comprising pressure elements (17), which are designed to apply a stress (S) on the pads (8), which is lower than the maximum compression strength (Cmax) of the base material of the electronic board 3.