Patch Electrical Connector With Segmented Weld Legs
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Solution Overview
Problem
Existing patch electrical connectors lack stability when connected to printed circuit boards (PCBs) due to insufficient fixation, often leading to shaking or detachment during use.
Innovation Solution
A patch electrical connector design featuring a housing with mounting cavities, conductive clips with clamping pieces and weld legs, where the conductive clip includes a conductive seat, clamping pieces, and weld legs that engage with the PCB and housing, providing a secure electrical connection with reduced weld area and enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the welding portion on the PCB is made larger to improve fixation, then the connection strength is improved, but the available space on the PCB is reduced and the structure becomes more complex
Solution Approach 1:
The connection structure is divided into two separate weld legs (first weld leg and second weld leg) instead of using a single large welding portion. This segmentation allows the connector to achieve strong fixation through multiple small weld points, reducing the total area required on the PCB while maintaining or improving connection strength.
2Strength
If the welding portion on the PCB is made larger to improve fixation, then the connection strength is improved, but the device complexity increases
Solution Approach 1:
The conductive clip serves multiple functions: it provides electrical connection through the first weld leg, structural support through the second weld leg, and mechanical engagement through the conductive seat and clamping pieces. This multi-functionality allows the connector to achieve strong fixation without requiring additional separate components, thereby reducing overall device complexity.
3Strength
If the welding portion on the PCB is made larger to improve fixation, then the connection strength is improved, but the manufacturing precision requirements increase
Solution Approach 1:
By dividing the connection into two separate weld legs with smaller individual welding portions, the patent reduces the impact of welding variability on overall connection strength. Each small weld point is easier to control with consistent precision, and the combined effect of multiple welds provides redundant security, lowering the overall manufacturing precision requirements compared to a single large weld.
Data Source
AI summary
The present disclosure provides a patch electrical connector, which comprises a housing, a conductive clip and a second weld leg. The housing has at least one mounting cavity provided therein. The number of conductive clip matches the number of the mounting cavity, and the conductive clip is adapted to the mounting cavity. The conductive clip comprises a conductive seat provided in the mounting cavity, at least one pair of clamping pieces electrically connected to the conductive seat, and a first weld leg electrically connected to the conductive seat and welded to the PCB board. The second weld leg has one end welded to the PCB board and the other end disposed in the housing. A wire or male connector is insertable into the mounting cavity and clamped to one pair of the clamping pieces to enable electric communication with the PCB.