Power Converter Lead Frame Spacer for PCB-Safe Assembly
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Solution Overview
Problem
In power converters, the bending of lead frames can cause them to return to their original position, leading to a gap between the lead frame and the case, which can result in damage to printed-circuit boards when screws are fastened, deteriorating the reliability of the converter.
Innovation Solution
A spacer is provided on the lead frame adjacent to the outlet opening, which is sandwiched between the lead frame and the case, preventing the lead frame from returning to its original position and ensuring proper contact with the printed-circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lead frame is bent to fix the case, then the case is fixed and the lead frame is positioned, but the lead frame returns to its original position causing a gap and potential damage to printed-circuit boards
Solution Approach 1:
A spacer is introduced as an intermediary component between the lead frame and the case. The spacer maintains the bent position of the lead frame by being sandwiched between these two components, preventing the lead frame from returning to its original position and eliminating gaps that could cause PCB damage during assembly.
2Ease of manufacture
If the lead frame is bent to extend vertically upward, then the case can be fixed, but the lead frame creates a gap with the case surface and may strike against and deform the printed-circuit board
Solution Approach 1:
The spacer serves as a mediator that enables the lead frame to maintain its vertically extended position for easy case fixing while simultaneously preventing excessive protrusion that would compromise manufacturing precision and damage the PCB during screw fastening operations.
Data Source
AI summary
A power converter includes a case including an outlet with an outlet opening in a principal surface thereof, and a wiring member having, as an external connection portion, a portion that extends out from the outlet opening and is bent at the outlet opening toward the principal surface. The external connection portion of the wiring member has a first surface facing the principal surface and includes a spacer provided on the first surface at a position adjacent to the outlet opening. The spacer is sandwiched between the first surface of the drawn-out portion and the principal surface of the case.