PCB Terminal Headers With Integrated Locking Cavities
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Solution Overview
Problem
Conventional terminal headers on printed circuit boards (PCBs) face issues with electrical terminals becoming bent, misaligned, or damaged during assembly, and require the use of alignment tools, making the mounting process difficult and prone to errors.
Innovation Solution
The design of improved male and female terminal headers with integrated terminal mounting cavities and locking members that retain electrical terminals within the headers before mounting to the PCBs, eliminating the need for alignment tools and ensuring proper alignment and secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrical terminals are positioned and held with an alignment tool during attachment to the PCB, then the terminals can be aligned with the PCB, but the terminals may become bent, misaligned, or damaged during the mounting of the male and female terminal headers
Solution Approach 1:
The patent applies preliminary action by pre-attaching the electrical terminals to the header body before mounting the entire assembly to the PCB. The terminals are secured to the header body with locking members in advance, which protects them during subsequent handling and mounting operations, preventing bending and damage that would occur if alignment tools were used during PCB attachment.
Solution Approach 2:
The invention segments the assembly process into two distinct stages: first attaching terminals to the header body, then mounting the complete header assembly to the PCB. This segmentation allows the terminals to be secured in a protected environment before facing the rigors of PCB mounting, thereby maintaining both alignment precision and terminal integrity.
2Ease of manufacture
If the male and female terminal headers are mounted to the PCB separately, then each header can be attached to the PCB, but the headers may be difficult to align and connect to each other
Solution Approach 1:
The patent merges the electrical terminals and the header body into a single pre-assembled unit. By combining these components before PCB mounting, the invention eliminates the need for separate alignment operations between male and female headers, as they are already positioned relative to each other in the assembled unit, greatly simplifying the connection process.
3Manufacturing precision
If alignment tools are used to position electrical terminals during PCB mounting, then terminal alignment can be achieved, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The invention performs terminal positioning in advance during the header assembly process, rather than during PCB mounting. This preliminary positioning eliminates the need for alignment tools during PCB attachment, reducing assembly process complexity while maintaining precise terminal positioning through the header body's built-in positioning features.
Data Source
AI summary
An electrical terminal header assembly is configured for attachment to a substrate and includes a header body having a terminal mounting cavity formed therein and a first locking member. An electrical terminal has a terminal body and a terminal post extending outwardly from the terminal body, is disposed in the terminal mounting cavity, and is retained therein by the first locking member. The terminal post extends outwardly from the header body and is configured for attachment to the substrate.