Low-Profile PCB Strain Relief Plug for Lead Wire Retention
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Solution Overview
Problem
Existing strain relief devices for connector wires on printed circuit boards are either too complex for high-volume production, exhibit weak structural integrity, or have excessive vertical profiles, making them unsuitable for low-profile applications like electric motors.
Innovation Solution
A strain relief plug with an elongated stem, an in-board flange that seats in a bore on the printed circuit board, an anchor with flexible barbs to prevent release, and a bar with turned ends to form lead wire channels, which restricts movement of lead wires while allowing for various angular orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing strain relief devices are used to protect solder joints, then reliability is improved, but device complexity increases
Solution Approach 1:
The strain relief device is divided into distinct functional segments: an anchor portion for securing to the PCB, a body portion for structural support, and a wire retention portion for capturing lead wires. This segmentation allows each part to perform its specific function efficiently while simplifying the overall design and manufacturing process.
Solution Approach 2:
The lead wires are nested within the wire retention portion of the device, which is itself nested within or attached to the body portion. This nested structure provides compact strain relief while maintaining simplicity in the overall device configuration.
2Reliability
If existing strain relief devices are used to protect solder joints, then reliability is improved, but manufacturing time increases
Solution Approach 1:
The device is pre-formed as a single integrated component with all functional portions (anchor, body, wire retention) already configured. This preliminary preparation eliminates the need for complex assembly operations during installation, allowing for rapid placement on the PCB and immediate wire retention functionality.
Solution Approach 2:
Multiple functions (strain relief, wire retention, structural support) are merged into a single integrated device that can be installed in one operation. This consolidation reduces the number of steps required during manufacturing while maintaining reliable protection of solder joints.
3Reliability
If existing strain relief devices are used to protect solder joints, then reliability is improved, but vertical profile increases
Solution Approach 1:
The device utilizes the lateral dimension (width) rather than the vertical dimension (height) to provide strain relief functionality. The wire retention portion extends laterally to capture lead wires, while the vertical profile remains minimal, matching the PCB thickness and maintaining a low overall height.
4Reliability
If existing strain relief devices are used to protect solder joints, then reliability is improved, but ease of manufacture decreases
Solution Approach 1:
The device is designed with clear functional segments that can be easily formed using standard manufacturing processes. The anchor portion, body portion, and wire retention portion are distinct but can be created in a single molding or fabrication operation, simplifying manufacturing while ensuring reliable performance.
Data Source
AI summary
A strain relief plug to restrict movement of wires on a printed circuit board, the strain relief plug having an elongated stem along a vertical axis of the strain relief plug. The strain relief plug has an in-board flange defined by the elongated stem, the in-board flange configured to seat in a bore defined by the printed circuit board. The strain relief plug has an anchor defined by a first end of the elongated stem configured to prevent the strain relief plug from releasing from the printed circuit board. The strain relief plug has a bar defined by a second end of the elongated stem and transverse the vertical axis, the bar forming wire channels. The strain relief plug provides strain relief for wires on the printed circuit board of an electric motor in a vertical dimension resembling the thickness of the printed circuit board.