Locking Terminal Connector Assembly for Circuit Board
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connector assemblies for circuit boards often apply residual transverse loads to the board during terminal insertion, leading to potential cracking and failure, and face challenges in efficiently connecting high-current terminals due to difficulties in soldering large terminals.
Innovation Solution
A connector assembly with locking terminals that mechanically connect to a circuit board without applying residual transverse loads, using a body made of electrically insulating polymeric material with locking terminals and surface mount terminals of varying sizes, where the terminals are soldered using a reflow process and feature projections and darts for secure alignment and interference fit, ensuring minimal residual loading and efficient electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connector terminals are inserted into circuit boards, then electrical connection is achieved, but residual transverse loads are applied to the board causing cracking and failure
Solution Approach 1:
The terminal is divided into multiple functional segments: a blade portion for electrical connection, a tab portion with projection for mechanical locking, and a slot portion for board engagement. This segmentation allows each portion to perform its specific function independently, enabling the projection to prevent residual loads while maintaining electrical connectivity.
Solution Approach 2:
The projection on the tab portion is designed to engage with the circuit board aperture before final insertion is completed. This preliminary engagement establishes a mechanical lock that prevents the terminal from applying residual transverse loads to the board during subsequent thermal cycling and mechanical stress, thereby preventing cracking before failure occurs.
2Power
If large terminals are used for high-current connections, then current carrying capacity is improved, but soldering becomes difficult and time-consuming
Solution Approach 1:
The invention replaces the traditional soldering mechanical process with a reflow soldering system that uses controlled thermal fields. The terminal geometry and material properties are optimized to work with automated reflow processes, allowing large high-current terminals to be connected efficiently without manual soldering, thereby improving productivity while maintaining power capacity.
3Reliability
If terminals are designed with secure mechanical connection features, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The terminal design merges multiple functions into a single integrated component: the blade provides electrical connection, the tab with projection provides mechanical locking, and the slot portion provides board engagement. This merging of functions into one piece reduces the number of separate components needed, thereby reducing overall device complexity while maintaining high connection reliability through the combined mechanical features.
Data Source
AI summary
A connector assembly is provided with a body that extends along a lateral length with a longitudinal height defined by a first body surface and an opposing second body surface. A locking terminal extends through the body and includes an elongate blade having a distal end for electrically connecting to a mating connector and a proximal end adapted to electrically connect to an electronic component with an aperture. At least one tab extends lengthwise from an intermediate portion of the blade and extends through the electronic component aperture. A projection extends outward from the tab such that the projection interferes with the aperture during insertion of the tab therethrough for deforming the tab. After insertion, the tab returns from the deformation and engages the projection to the electronic component for retaining the tab within the aperture.