Electronic Component Lead Terminal Deformation Prevention
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Solution Overview
Problem
Conventional electronic component assembly structures in moving objects like automobiles face deformation issues with lead terminals due to concentrated load during assembly, affecting connection states and holding forces.
Innovation Solution
Incorporating an insulating member along the end surface of the electronic component main body to support lead terminals, which reduces stress on the terminals during assembly and prevents deformation by distributing the load to the insulating member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If lead terminals are bent into L shape to reduce height dimension, then the height dimension of the relay module is reduced, but the lead terminals may be permanently deformed due to concentrated load during assembly
Solution Approach 1:
The insulating member is attached to the relay main body in advance, creating a support structure before the lead terminals are inserted into the terminal fittings. This preliminary support prevents the concentrated load from causing permanent deformation during the assembly process.
Solution Approach 2:
The insulating member acts as an intermediary between the relay main body and the lead terminals. It distributes the load from the lead terminals to the relay main body, preventing direct concentration of stress on the bent portions of the L-shaped lead terminals.
2Strength
If lead terminals are inserted into terminal fittings against spring force, then the relay can be held in the housing member, but the concentrated reaction force may cause permanent deformation of the lead terminals
Solution Approach 1:
The insulating member is pre-attached to the relay main body to provide support before the lead terminals are inserted. This preliminary support structure ensures that the reaction force from the spring portions is distributed rather than concentrated, preventing permanent deformation while maintaining the necessary holding force.
Solution Approach 2:
The insulating member serves as a mediator that distributes the reaction force from the terminal fittings to the relay main body. This intermediary structure allows the relay to be held securely while preventing stress concentration that would cause manufacturing precision issues.
3Ease of manufacture
If relay main body is placed on end surface of holding member, then assembly is simplified, but the height dimension of the relay module increases
Solution Approach 1:
The lead terminals are bent into L shapes, changing their spatial configuration from straight to angular. This dimensional change allows the relay main body to be positioned lower, reducing the overall height dimension while maintaining assembly simplicity through the insulating member support.
Data Source
AI summary
An electronic component having plural lead terminals protruding from side surfaces of a component main body is inserted and accommodated in a housing member, and the lead terminals are brought into contact with plural terminal fittings held in the housing member to assemble the electronic component into the housing member. Each of the lead terminals includes a base end protruding from at least one side surface of the component main body and a contact portion connected to the base end to droop along the side surface. The component main body is provided with an insulating member which is located to contact or face the base ends from a side of an end surface of the component main body which is most distant from a bottom wall of the housing member in assembling the electronic component into the housing member. Accordingly, it is possible to suppress deformation of the lead terminals.