PCB Terminals with Axially Spaced Insertion Tabs
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Solution Overview
Problem
Conventional printed circuit board (PCB) assemblies have limitations in reducing the centerline distance between adjacent electrical terminals, making it difficult to achieve a smaller package size for junction boxes.
Innovation Solution
The design of improved electrical terminals with axially spaced insertion tabs allows for closer mounting of adjacent terminals by altering the configuration of the mounting member, shoulders, and insertion tabs, enabling a reduced centerline distance between terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional terminals with co-planar insertion tabs are used, then the terminals can be easily mounted on the PCB, but the centerline distance between adjacent terminals cannot be reduced
Solution Approach 1:
The insertion tabs are repositioned from a co-planar arrangement to an axially spaced arrangement, where one insertion tab is positioned at a different axial location than the other. This dimensional change in the tab configuration allows adjacent terminals to be mounted closer together along the PCB surface while maintaining proper insertion and engagement functionality.
2Area of stationary object
If the centerline distance between adjacent terminals is reduced, then the PCB assembly size can be reduced, but the terminals may come into contact with each other
Solution Approach 1:
By spacing the insertion tabs axially at different positions along the terminal body, the patent creates a staggered configuration that prevents adjacent terminals from making contact even when their centerlines are closely spaced on the PCB. This axial separation provides an additional dimensional buffer that maintains electrical isolation while enabling compact layout.
3Volume of stationary object
If conventional co-planar insertion tabs are used, then the manufacturing process is simple, but the package size of the junction box cannot be reduced
Solution Approach 1:
The patent modifies the terminal structure by positioning insertion tabs at different axial locations rather than in a co-planar arrangement. This dimensional reconfiguration enables reduced junction box volume through closer terminal spacing, while the tabs remain integrally formed with the terminal body, maintaining manufacturing simplicity through standard molding or forming processes.
Data Source
AI summary
A printed circuit board includes a surface and having first and second adjacent apertures. First and second electrical terminals include respective ends disposed in the first and second apertures of the printed circuit board, respective shoulders adjacent to the ends of the first and second electrical terminals and engaged with the surface of the printed circuit board, and respective insertion tabs adjacent to the shoulders of the first and second electrical terminals and located respective first and second distances away from the surface of the printed circuit board. The first and second distances are different such that the first and second insertion tabs do not touch one another.