Lead Plate Holder Structure for Suppressing Bend Spring Back
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Solution Overview
Problem
Existing electric devices face issues with lead plate spring back during assembly, leading to welding and soldering defects due to separation from the circuit board, necessitating complex fixing mechanisms that increase cost and reduce design flexibility.
Innovation Solution
A holder is used to abut on and hold the upper surface of bent lead segments, suppressing spring back and ensuring stable connection through laser welding without additional fixing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixing mechanism such as screws or jigs is used to suppress spring back, then the lead plate can be reliably fixed at bent positions, but the number of components increases and cost increases
Solution Approach 1:
The holder is integrated into the circuit board structure, combining the functions of the circuit board and the fixing mechanism into a single component. The holder includes a holding portion that directly contacts and suppresses spring back of the lead plate, eliminating the need for separate screws or jigs while maintaining reliable fixing stability
Solution Approach 2:
The holder structure is designed to automatically suppress spring back through its geometric configuration. The holding portion of the holder naturally opposes the spring back direction when the lead plate is bent, providing self-contained spring back suppression without requiring additional active fixing components
2Reliability
If a fixing mechanism such as screws or jigs is used to suppress spring back, then welding and soldering can be performed stably, but the design flexibility is limited
Solution Approach 1:
The holder is merged with the circuit board, allowing the circuit board design to directly incorporate spring back suppression functionality. This integration enables greater design flexibility as the holder can be customized within the circuit board layout without being constrained by separate fixing mechanism designs
Solution Approach 2:
The holder provides localized spring back suppression exactly where needed at the lead plate connection points. The holding portion is positioned to contact only the specific area requiring stabilization during welding, allowing other areas of the circuit board to maintain their original design flexibility
3Ease of operation
If the lead plate is bent to specific positions, then electrical connection can be achieved, but spring back occurs and separation from circuit board happens
Solution Approach 1:
The holder is designed to preemptively counteract spring back forces before welding occurs. The holding portion contacts the lead plate in a position that opposes the spring back direction, preventing separation during the welding process and ensuring precise connection without requiring post-bending adjustments
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
The holder suppresses spring back, enhancing stability and reliability of the lead plate connections, simplifying the manufacturing process and reducing the need for extra fixing mechanisms.
Implementation Method 1
spring back occurs and the lead plates invariably try to return to original shapes thereof
Implementation Method 2
connecting the lead plate to the circuit board through laser welding with the lead plate held by the holder portion
Data Source
AI summary
Spring back is suppressed with a simple configuration. An electric device includes lead plate including bent segment bent along bend line, circuit board electrically connected to bent segment of lead plate, and holder that holds lead plate. Holder includes holder portions that lock part of upper surfaces of bent segments. Holder portion is configured to abut on and hold the part of the upper surface of bent segment while the holder portion opposes a direction of spring back caused by bent segment of lead plate being bent along bend line. Circuit board includes connection region electrically connected to lead plate. Bent segment is electrically connected to connection region.