Offset Electrical Terminal Structure for Compact PCB Assembly
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Solution Overview
Problem
Existing electrical terminals face challenges in being disposed close enough together due to outer dimension limitations and insertion depth restrictions, which can lead to short-circuiting and increased assembly complexity, especially in large-scale production.
Innovation Solution
The design includes a body with a first tab and a vertically offset second tab, where the first tab contacts the circuit board, and the second tab does not, allowing for closer alignment without short-circuiting, using a configuration with a projection and recesses to manage copper plating displacement and insertion depth, and enabling simultaneous connection of multiple terminals in a reel configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If terminals are disposed closer together to reduce circuit board size, then area of circuit board is reduced, but risk of short-circuiting increases
Solution Approach 1:
The patent introduces a vertical dimension to the tab arrangement by offsetting the second tab from the first tab in the vertical direction. This dimensional change allows tabs to be positioned closer horizontally without contacting the circuit board simultaneously, reducing short-circuit risk while enabling closer terminal spacing on the circuit board.
Solution Approach 2:
The patent employs asymmetric positioning of tabs where the second tab is vertically offset from the first tab. This asymmetric arrangement creates different contact patterns for adjacent terminals, ensuring that even when terminals are closely spaced, their tabs do not align to contact the circuit board at the same location, thereby preventing short-circuits.
2Productivity
If terminals are disposed closer together, then productivity is improved through compact assembly, but device complexity increases due to insertion depth restrictions
Solution Approach 1:
By offsetting tabs in the vertical dimension, the patent enables closer horizontal terminal spacing without increasing insertion depth complexity. The vertical offset creates natural separation in contact timing, allowing compact terminal arrangements to be assembled efficiently while managing insertion depth through the vertical positioning of tabs rather than complex depth control mechanisms.
3Reliability
If both tabs contact the circuit board simultaneously, then connection reliability is improved, but terminal spacing must be increased to prevent short-circuiting
Solution Approach 1:
The vertical offset between tabs introduces a temporal dimension to contact sequence. The first tab contacts the circuit board before the second tab, allowing both tabs to maintain reliable connections while preventing simultaneous contact that would cause short-circuits in closely spaced terminals. This resolves the contradiction by using vertical positioning to control contact timing.
Solution Approach 2:
The asymmetric vertical positioning of tabs creates different contact sequences for adjacent terminals. This asymmetry ensures that while each terminal maintains reliable dual-tab connection, the offset positioning prevents simultaneous contact between adjacent terminals, enabling compact circuit board layout without sacrificing connection reliability.
Data Source
AI summary
An electrical terminal includes a body, a first tab extending from a first side of the body, and a second tab extending from a second side of the body. The second tab may be vertically offset, in a longitudinal direction of the body, from the first tab. The first tab and the second tab may extend in substantially opposite directions. An offset distance between the first tab and the second tab may be less than about half of a height of the first tab. The first tab may be disposed such that upon connection of the electrical terminal with a circuit board, the first tab contacts a surface of the circuit board. The second tab may be disposed such that upon connection of the electrical terminal with said circuit board, the second tab does not contact the circuit board.