Mass-Contact Module Support Structure for Stable PCB Press-In Contacts
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Solution Overview
Problem
Existing mass-contact modules for control devices in vehicles lack flexibility in configuration and retrofitting, and they often suffer from movement issues between the circuit board and the press-in contact, leading to increased transition resistance and potential failure. Additionally, they are prone to corrosion due to inadequate potting compound integration.
Innovation Solution
A mass-contact module with a press-in contact and a supporting part that forms a force-conducting connection with the circuit board by integrating a form-fitting and/or integral connection to a potting compound. This design eliminates the need for specific guides in the electronics housing, allows for flexible arrangement, and prevents moisture ingress, thus ensuring corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If guides are integrated into the electronics housing for the mass contact, then movement between the press-in contact and circuit board is prevented, but the configuration freedom of the control device is highly restricted
Solution Approach 1:
The invention separates the guiding function from the housing by introducing a separate supporting part. This supporting part is connected to the press-in contact and provides the necessary guidance, while the housing remains free from integrated guides, thus maintaining configuration freedom.
Solution Approach 2:
The supporting part acts as an intermediary element between the press-in contact and the housing. It provides the guiding and supporting functions without requiring integration into the housing structure, allowing flexible arrangement of mass contacts.
2Ease of manufacture
If the press-in contact is pressed directly into the circuit board, then electrical connection is achieved, but movement occurs during operation causing increased transition resistance and potential failure
Solution Approach 1:
The supporting part is connected to the press-in contact before insertion into the circuit board. This preliminary connection provides structural support and guidance during the pressing operation, ensuring proper positioning and preventing movement that would lead to connection failure.
Solution Approach 2:
The supporting part can be formed from composite materials or different materials than the press-in contact, providing both mechanical support and electrical insulation where needed, while maintaining the electrical conductivity of the contact itself.
3Reliability
If potting compound is used to secure the mass contact, then movement is prevented, but corrosion occurs due to inadequate connection to the metallic mass contact
Solution Approach 1:
The supporting part serves as an intermediary between the potting compound and the press-in contact. The potting compound bonds to the supporting part, which then provides structural support to the press-in contact, preventing direct contact between the compound and metallic contact that would cause corrosion.
Solution Approach 2:
The supporting part can be designed as a sacrificial or replaceable element that protects the more critical press-in contact from corrosion. If degradation occurs, the supporting part can be replaced without replacing the entire mass contact assembly.
Data Source
AI summary
A mass-contact module for a control device includes a press-in contact extending in a longitudinal direction and having a connector portion for forming an electrically conductive press-in connection to a circuit board and an end portion which is at a distance in the longitudinal direction and is configured to make contact with a contact surface. A supporting part is connected to the press-in contact and is configured to form a force-conducting connection between the circuit board and the press-in contact by forming a form-fitting and/or integral connection to the potting compound. A control device includes such a mass-contact module. An assembly method is for assembling a corresponding control device.