Polymeric Base for Electronic Component Assembly
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Solution Overview
Problem
Large electronic components mounted on printed circuit boards are mechanically unstable due to their size and shape, leading to potential failure of electrical connections under vibration, especially with solder-based connections prone to cracks and lead dislodgment.
Innovation Solution
An electronic component assembly featuring a polymeric base with holes and channels that guide leads to metal bushings or pins, providing a solderless connection and mechanical stability by using eye-shaped terminals for secure press fits onto a support, ensuring robust electrical and mechanical reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solder-based connections are used to mount large electronic components on PCBs, then electrical connection is achieved, but mechanical stability deteriorates under vibration leading to cracks and lead dislodgment
Solution Approach 1:
The patent introduces a polymeric base as an intermediary component between the electronic component and the PCB. This base provides a mechanically stable mounting structure with integrated channels and contact points, replacing the fragile solder-based connection system. The base acts as a mediator that transfers both mechanical support and electrical connection functions, eliminating the weakness of direct solder joints on large components.
Solution Approach 2:
The invention replaces the traditional mechanical soldering system with a press-fit mechanical connection system. The electronic component is mechanically secured to the polymeric base through friction fit and geometric interlocking, while electrical connection is achieved through dedicated contact points and conductive paths within the base structure, eliminating reliance on brittle solder joints.
Data Source
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AI summary
An electronic component assembly includes an electrical component (12) assembled to a base (14) and mounted to a support (16). The component electrical leads (20,21) protrude through holes, along a channel, and make contact with connectors (38) on the base. The base (14) is formed of a polymeric material and contains protrusions (44) for mechanically supporting the electrical component. When the base is mounted to the support, the connectors complete the electrical connection between the electrical component (12) and the support (16).