PCB-to-Conductor Mortise-Tenon Joint for Low-Resistance Assembly
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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 failure risks due to mechanical fixation, especially under high vibration loads.
Innovation Solution
A joint is created by forming a tenon monolithically from the solid electrical conductor material, which is pressed into a through-hole with an electrically conductive lining in the printed circuit board, providing both mechanical and electrical contact without separate fixation elements.
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 which increase device complexity and produce scrap during manufacturing
Solution Approach 1:
The patent merges the connection element with the solid electrical conductor by forming the tenon monolithically from the conductor material itself. This eliminates the separate connection element, reducing the number of parts and eliminating scrap production during manufacturing, while maintaining the attachment function between the printed circuit board and conductor.
2Adaptability or versatility
If a separate connection element is used, then the attachment can be established, but material restrictions apply regarding weldability and solderability
Solution Approach 1:
By integrating the connection element directly into the solid electrical conductor as a monolithic structure, the patent eliminates the need for separate materials with specific weldability or solderability requirements. The tenon is formed from the same material as the conductor, removing material compatibility constraints while maintaining attachment capability.
3Reliability
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, especially under vibration load
Solution Approach 1:
The patent eliminates separate mechanical fixation by forming the tenon monolithically from the solid electrical conductor material. This integration removes additional interconnections that could fail over time, particularly under vibration loads, while maintaining secure attachment through the friction fit between the tenon and through-hole lining.
4Reliability
If separate fixation elements are used, then the attachment can be established, but more boundary areas between parts are present, leading to higher electrical transfer resistance
Solution Approach 1:
By integrating the connection element into the solid electrical conductor as a monolithic structure, the patent reduces the number of boundary areas between parts. This minimizes electrical transfer resistance and improves the quality of the electrical connection between the printed circuit board and the conductor.
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, minimizes interconnections, lowers electrical transfer resistance, and improves the reliability and performance of electrical assemblies by eliminating separate connection elements, particularly in measurement applications.
Implementation Method 1
a tenon, which is pressed in into the through-hole and is in frictional as well as in electrical contact with the electrically conductive lining
Data Source
Figure 1
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AI summary
The present invention relates to a preferably rigid joint (3) for attaching a printed circuit board (20) to a solid electrical conductor (22), wherein the joint (3) comprises an electrically conductive lining (34), which lines an inner surface of a through-hole (26) in the printed circuit board (20), and a tenon (62) pressed in into the through-hole (26) being in frictional as well as in electrical contact with the electrically conductive lining (34), wherein the tenon (62) is monolithically formed from the material of the solid electrical conductor (22). In the joint (3), the lining (34) of the through-hole (26) functions as a mortise for the tenon (62), while it also functions to establish an electrical connection. Further, the present invention relates to an electrical assembly (2) with such a joint (3), an electrical measurement device (1) with such an electrical assembly (2) and a method for the manufacturing of such an electrical assembly (2).