PCB Contact Carrier for Flexible Assembly
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Solution Overview
Problem
Current automated processes for equipping printed circuit boards with electrical components are economically viable only for large quantities, making individual solutions and small series production expensive and complex, often requiring manual intervention.
Innovation Solution
A device featuring a contact carrier with conductive contact elements and a splicing element for wire management, allowing for automated connection methods like SMT or Press-In, enabling flexible and cost-effective assembly of printed circuit boards for both large and small series production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated soldering processes (SMT or THR) are used to equip printed circuit boards with electrical components, then manufacturing efficiency and consistency are improved, but production cost increases significantly for small series and individual solutions
Solution Approach 1:
The device segments the connection system into modular components: a contact carrier with multiple contact elements that can be independently configured, and a separate electrical component with connection contacts. This modularity allows the same automated mounting process to be used for different configurations without requiring complete retooling, thereby reducing costs for small series production while maintaining manufacturing efficiency.
Solution Approach 2:
The contact carrier is designed as a universal base structure that can accommodate different types of electrical components and connection configurations. The same contact carrier platform can be used across multiple applications and product variants, allowing automated manufacturing processes to serve multiple purposes and reducing the per-unit cost for small production runs.
2Ease of manufacture
If manual assembly methods are used for individual solutions and small series, then production cost is reduced, but manufacturing complexity and time consumption increase
Solution Approach 1:
The contact elements are pre-configured on the contact carrier with their connection contacts positioned and oriented correctly before assembly. The electrical component is prepared with its connection contacts ready for insertion. This preliminary preparation eliminates the need for complex manual positioning and alignment during assembly, reducing both assembly complexity and time while maintaining cost-effectiveness for small series production.
3Reliability
If connection contacts are directly soldered to the printed circuit board, then electrical connection reliability is improved, but heat-sensitive components may be damaged during the soldering process
Solution Approach 1:
The connection system is segmented into two stages: first, the contact carrier is soldered to the printed circuit board (creating a robust electrical connection); second, the electrical component with heat-sensitive connection contacts is inserted into the contact carrier without requiring soldering. This segmentation allows the soldering heat to affect only the contact carrier and PCB, protecting heat-sensitive components from thermal damage while maintaining connection reliability.
Solution Approach 2:
The contact carrier acts as an intermediary between the printed circuit board and the heat-sensitive electrical component. It provides a thermally isolated mounting platform that can be soldered to the PCB while protecting the subsequently inserted heat-sensitive component from soldering heat, thereby maintaining electrical connection reliability without exposing sensitive components to harmful temperatures.
4Ease of operation
If press-in technology is used to connect components to the printed circuit board, then assembly simplicity is improved, but mechanical strength and electrical connection reliability may be reduced
Solution Approach 1:
The connection function is segmented between the contact carrier and the electrical component. The contact carrier provides the robust mechanical and electrical connection to the PCB through soldering or press-in methods. The electrical component simply needs to be inserted into the contact carrier, which provides the necessary mechanical support and electrical contact. This segmentation allows the use of simpler press-in technology for the component installation while maintaining high reliability through the dedicated contact carrier connection to the PCB.
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
Facilitates automated and cost-effective assembly of printed circuit boards, allowing for flexible adaptation to various applications with reduced manual effort, while ensuring secure and stable electrical connections.
Implementation Method 1
at least one free-standing connection contact protruding from the connection side of the contact carrier for making electrical contact with the printed circuit board
Implementation Method 2
a clamping area which has at least two webs between which a slot is formed for accommodating the respective electrical connection of the electrical component or the respective wire of the electrical cable
Data Source
Figure 1a~1e
Figure 2a~2b
Figure 3a~3c
AI summary
In the prior art, there is the disadvantage that automatic population methods for printed circuit boards are worthwhile only for large numbers. On the other hand, individual solutions and small series are expensive and complicated and are currently often implemented in manual work. The aim of the invention is to specify a device which facilitates the population of a printed circuit board economically, even for small series. This aim is achieved by a device which has a contact carrier (2) having contact elements (23, 23'). Said device can firstly be installed on printed circuit boards (4) in high numbers in an automated manner and, secondly, permits the connection of electric components (1) and/or electric cables (5) with only little manual effort.