Inter-Substrate Connection Terminal for Vibration-Resistant Electrical Linking
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Solution Overview
Problem
Existing inter-board connection methods, such as harnesses and connectors, face issues with contact failure due to springback and gel material invasion, leading to unreliable electrical connections, especially in vibration-prone environments like vehicle-installed electric compressors.
Innovation Solution
An inter-board connection terminal featuring a group of metal terminals inserted into through-holes with paired resin linking members that form a row, providing positioning protrusions and integrally molded legs for stable alignment and soldering, ensuring reliable electrical connections without risk of springback or gel material interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a harness or flexible printed board is employed to connect two boards, then electrical connection between boards is achieved, but contact failure occurs due to bending springback
Solution Approach 1:
The invention divides the connection structure into discrete metal terminals individually inserted into through-holes, rather than using a continuous flexible printed board. Each terminal is independently secured in the through-hole, eliminating the bending springback issue that affects flexible boards while maintaining electrical connectivity.
Solution Approach 2:
The invention extracts the problematic flexible printed board component and replaces it with rigid metal terminals that are inserted into and secured by through-holes. This extraction removes the source of bending springback while preserving the essential function of electrical connection between boards.
2Reliability
If a connector is employed to connect two boards, then electrical connection is established, but contact failure occurs due to fitting issues
Solution Approach 1:
The through-holes are pre-formed in the boards at precise locations, and the metal terminals are designed to fit into these pre-prepared openings. This preliminary preparation of the connection path simplifies the assembly process and ensures proper alignment, eliminating fitting issues that complicate connector installation.
Solution Approach 2:
The metal terminals, when inserted into the through-holes, automatically achieve proper positioning and alignment. The through-holes themselves serve as the guiding and securing mechanism, eliminating the need for separate fitting operations or adjustment procedures that would otherwise be required with traditional connectors.
3Adaptability or versatility
If an inverter is employed in a vehicle-installed electric compressor, then the compressor can be controlled, but springback becomes more prominent due to road-surface vibrations
Solution Approach 1:
The rigid metal terminals inserted into through-holes provide inherent resistance to vibration-induced springback before vibrations occur. The through-hole structure acts as a pre-established anchor that prevents the connection points from deflecting under vibrational stress, cushioning against the effects of road-surface vibrations.
Solution Approach 2:
The invention applies rigid metal terminals at the specific locations where electrical connections are needed, providing localized resistance to vibration. Rather than making the entire structure rigid, only the connection points are reinforced with terminals that resist springback, while the rest of the inverter and compressor components maintain their original flexibility.
4Reliability
If a board is embedded in a gel material, then protection is provided, but gel material invades the fitting portion of the connector, making contact failure more likely
Solution Approach 1:
The invention extracts the connection terminals from the gel-embedded region by inserting them through through-holes that pass completely through the board. The terminals extend beyond the gel material on both sides, removing them from the harmful gel environment while maintaining their electrical connection function.
Solution Approach 2:
The through-holes serve as intermediaries that allow the metal terminals to pass through the board and extend into regions free of gel material. The holes act as channels that separate the terminals from the harmful gel environment, preventing gel invasion while maintaining structural integrity.
Data Source
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AI summary
Provided are an inter-sub-strate connection terminal that is capable of improving workability and productivity by enabling easy electrical connection between 2 substrates and which assures the reliability of the electrical connection, and an inverter and an electric compressor that use the inter-substrate connection terminal. The inter-substrate connection terminal (24) is provided with a group of many metal terminals (25) that are respectively inserted into substrate-side through holes at both ends so as to electrically connect the 2 substrates. A pair of linking members (27, 28) are provided for the group of many metal terminals (25) with a predetermined space from each other, said linking members integrally connecting, in rows, the base sections around the parts where the both ends of the group of many metal terminals (25) are to be inserted into the substrate-side through holes.