PCB-to-Conductor Press-Fit Joint for Vibration-Stable Contact
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Solution Overview
Problem
Conventional methods for attaching printed circuit boards to solid electrical conductors require additional connection elements that lead to material restrictions, scrap production, and increased risk of interconnection failures, especially under high vibration loads.
Innovation Solution
A joint that uses a monolithically formed tenon from the electrical conductor material, pressed into a through-hole with an electrically conductive lining, eliminating the need for separate fixation elements and reducing interconnections, thereby enhancing mechanical and electrical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separate connection element is used to attach the printed circuit board to the solid electrical conductor, then the attachment can be established, but additional parts are required and scrap is produced during manufacturing
Solution Approach 1:
The connection element is merged with the solid electrical conductor by monolithically forming the tenon from the conductor material itself. This integration eliminates the separate connection element, thereby eliminating scrap production from manufacturing additional parts while maintaining the attachment function.
Solution Approach 2:
The solid electrical conductor is given multiple functions: it serves both as the electrical conductor and as the structural element containing the tenon for mechanical attachment. This multi-functionality eliminates the need for separate connection elements and reduces material waste.
2Ease of manufacture
If a separate connection element is used, then the attachment can be established, but material restrictions apply regarding weldability and solderability
Solution Approach 1:
The connection element and electrical conductor are merged into a single monolithic structure. This allows the use of any electrically conductive material without being constrained by the specific weldability or solderability requirements that would apply to separate connection elements, thereby expanding material selection flexibility.
3Ease of manufacture
If mechanical fixation of the connection element is applied, then the attachment can be established, but additional interconnections are created that may fail over time
Solution Approach 1:
The connection element is merged with the electrical conductor to form a monolithic structure with the tenon. This integration eliminates separate mechanical fixation points and interconnections, thereby reducing the risk of failure over time while maintaining secure attachment.
Solution Approach 2:
The problematic mechanical fixation and associated interconnections are extracted from the design by using a monolithic structure. The tenon is directly formed from the conductor material without requiring separate fixation mechanisms, eliminating potential failure points.
4Ease of manufacture
If a separate connection element is used, then the attachment can be established, but the electrical transfer resistance increases
Solution Approach 1:
The connection element and electrical conductor are merged into a monolithic structure, creating a continuous electrical path without additional contact interfaces. This eliminates the electrical transfer resistance that would arise from separate connection elements and their contact surfaces.
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
This solution reduces scrap production, lowers electrical transfer resistance, and decreases the risk of interconnection failures, improving both economic efficiency and performance by eliminating the need for additional parts and interconnections.
Implementation Method 1
The tenon is in frictional and electrical contact with the electrically conductive lining
Data Source
AI summary
A joint for attaching a printed circuit board to an electrical conductor includes an electrically conductive lining that lines an inner surface of a through-hole in the printed circuit board and a tenon pressed in the through-hole. The tenon is in frictional and electrical contact with the electrically conductive lining. The tenon is monolithically formed from a material of the electrical conductor.