PCB Battery Tab Fixation Using Deflectable Conductive Prongs
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Solution Overview
Problem
Existing methods for assembling Tire Pressure Monitoring Systems (TPMS) components, such as soldering PCBs and batteries, face challenges like complex fixture requirements, solder imperfections, and high force-induced component cracks, along with lengthy or costly glue curing processes.
Innovation Solution
A PCB holder with deflectable electrically-conductive prongs that exert a compressive securing force on the PCB during insertion, mechanically connected to a battery pole, providing both mechanical and electrical links, and featuring spring-like projections for stable fixation within a housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to join PCB and battery with metal tabs, then electrical connection is achieved, but complex fixtures are required for alignment and soldering imperfections occur
Solution Approach 1:
The patent merges the mechanical retention function and electrical connection function into a single integrated battery tab structure. The tab serves dual purposes: providing electrical connectivity between battery and PCB while simultaneously acting as a mechanical fastener that secures the PCB in place, eliminating the need for separate soldering fixtures and alignment equipment.
Solution Approach 2:
The invention extracts the soldering operation entirely from the assembly process by replacing it with a mechanical insertion mechanism. The deflectable tab design allows the PCB to be simply inserted into the housing without any soldering, removing the complexity of soldering fixtures and the risk of solder defects.
2Stability of the object's composition
If clips are used to hold PCB and battery, then mechanical retention is achieved, but high forces cause cracks in sensitive components
Solution Approach 1:
The patent changes the mechanical parameter of retention force from high (clips) to low ( deflectable tab compression). The deflectable tab provides sufficient mechanical retention through spring-like compression forces that are gentle enough to avoid cracking sensitive PCB components while still securing the assembly firmly in place.
3Stability of the object's composition
If glue is used for fixation, then PCB is held in place, but lengthy curing time and costly process are required
Solution Approach 1:
The patent replaces the chemical fixation system (glue requiring curing time and oven processing) with a mechanical fixation system (deflectable tabs providing immediate retention). The spring-like tabs provide instant mechanical retention upon insertion, eliminating the lengthy curing process and associated costs while achieving equivalent or superior fixation stability.
4Ease of manufacture
If soldering is performed outside housing, then PCB and battery can be joined, but alignment complexity increases
Solution Approach 1:
The patent merges the alignment and connection functions into the housing structure itself. The deflectable tabs are pre-formed as integral parts of the battery assembly, with their geometry designed to automatically align with and secure the PCB edges upon insertion, eliminating the need for external alignment fixtures or complex positioning procedures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Simplifies the assembly process, reduces the risk of component damage, and eliminates the need for complex fixtures or lengthy curing processes, resulting in a more reliable and cost-effective TPMS device.
Implementation Method 1
at least one deflectable electrically-conductive prong, with a deflectable proximal end configured for retaining and exerting pressure on the edge of a PCB... the at least one deflectable electrically-conductive prong is configured to deflect during insertion of the PCB and exert a compressive securing force on an operably inserted PCB
Data Source
AI summary
A PCB holder for holding a PCB, and a method of assembling such a holder, are disclosed. The holder comprises a housing and at least one deflectable electrically-conductive tab or prong with a deflectable proximal end configured for retaining and exerting pressure on the edge of a PCB and a distal end mechanically secured to a pole of a battery, and a deflectable middle portion connecting the proximal end and the distal end, wherein the at least one deflectable electrically-conductive terminal prong is configured to deflect during insertion of the PCB and exert a compressive securing force on an operably inserted PCB.