PCB Terminal Clamp Structure for Faster Component Assembly
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Solution Overview
Problem
Conventional surface mount technology becomes increasingly complex and time-consuming as the number of electronic components on circuit boards grows, making assembly of miniaturized and lightweight electronic products, such as those in automobiles, difficult due to the need for precise soldering and adhesion of numerous components.
Innovation Solution
A terminal structure with a terminal body, locking means, insertion unit, and holding mechanism that includes clamping arms and a clamping space to securely attach electronic elements to a circuit board, allowing for quick and exact assembly by locking the insertion unit into conducting holes and clamping lead legs between the arms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional surface mount technology is used to assemble electronic components on circuit boards, then electrical connectivity and functionality are achieved, but assembly time increases and manufacturing complexity increases due to the need for precise soldering and adhesion of numerous components
Solution Approach 1:
The terminal structure is divided into distinct functional modules: a terminal body, a locking means for securing the terminal to the circuit board, an insertion unit for electrical connection, and a holding mechanism for supporting electronic elements. This segmentation allows each module to be manufactured and assembled independently, simplifying the overall assembly process and reducing manufacturing complexity while maintaining productivity benefits.
Solution Approach 2:
The terminal structure acts as an intermediary component between the circuit board and electronic elements. Instead of directly soldering numerous electronic components to the circuit board, the terminal provides a standardized interface with conducting holes that simplify connections. This intermediary structure reduces assembly complexity by replacing multiple precise soldering operations with a single terminal installation and electronic element placement process.
2Reliability
If conventional surface mount technology is used with numerous electronic components, then circuit functionality is achieved, but the soldering work becomes more difficult and time-consuming
Solution Approach 1:
The terminal structure is pre-assembled with the locking means and insertion unit integrated into the terminal body before being mounted on the circuit board. This preliminary assembly ensures that the connection structure is already prepared and positioned correctly, eliminating the need for time-consuming on-site adjustments and rework. The pre-assembled terminal can be quickly installed by inserting it into the circuit board's conducting holes, significantly reducing assembly time while maintaining connection reliability.
Solution Approach 2:
The holding mechanism replaces traditional mechanical soldering and adhesion methods with a clamping-based securing system. The clamping arms and clamping space provide mechanical retention for electronic elements through friction and geometric interlocking, eliminating the need for thermal soldering processes. This substitution reduces assembly time by removing heating cycles and cooling periods while ensuring reliable mechanical and electrical connections.
3Weight of moving object
If miniaturized and lightweight electronic products are designed, then product size and weight are reduced, but assembly of electronic components becomes more complicated and difficult
Solution Approach 1:
The terminal structure serves multiple functions simultaneously: it provides electrical connection through conducting holes, mechanical support for electronic elements via the holding mechanism, and secure mounting to the circuit board through the locking means. This multi-functionality eliminates the need for separate components for each function, reducing the overall number of parts and simplifying assembly procedures in miniaturized products while maintaining lightweight design.
Solution Approach 2:
The terminal structure merges the functions of electrical connection, mechanical support, and mounting security into a single integrated component. By combining these functions that would traditionally require separate components and assembly steps, the terminal simplifies the manufacturing process for miniaturized products. The integrated design reduces assembly complexity by eliminating multiple discrete assembly operations while keeping the product lightweight and compact.
Data Source
AI summary
A terminal structure includes a terminal body, a locking means formed on at least one face of the terminal body, an insertion unit extending from a first end of the terminal body, and a holding mechanism extending from a second end of the terminal body. The insertion unit is mounted on a circuit board. The circuit board defines multiple conducting holes. The insertion unit is inserted into and locked in one of the conducting holes of the circuit board. The holding mechanism includes two opposite clamping arms and a clamping space defined between the two clamping arms. An electronic element is held by the holding mechanism. The electronic element has multiple lead legs. One of the lead legs of the electronic element is clamped between the two clamping arms and held in the clamping space.