Press-Fit Connector Alignment Through Heat Sink and PCB Guides
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Solution Overview
Problem
Conventional circuit connection apparatuses face challenges in accurately positioning press-fit terminals with through-holes of a circuit board spaced apart from the housing of a connector, leading to increased component count, manufacturing costs, and potential buckling issues due to misalignment.
Innovation Solution
A circuit connection apparatus with a connector having positioning protruding portions and a heat sink with a guide receipt portion, along with a circuit board featuring board positioning guides, allows for accurate alignment without requiring a terminal-alignment member, using a simple assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a terminal-alignment member is added to facilitate press-fit terminal insertion, then the ease of operation improves, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent integrates the alignment function directly into the housing structure by forming a guide hole within the housing body itself, rather than using a separate terminal-alignment member. This merging of functions reduces component count while maintaining the alignment and insertion facilitation capability.
Solution Approach 2:
The housing serves multiple functions: it provides structural support, contains the guide hole for alignment, and facilitates press-fit terminal insertion. By making the housing multi-functional, the patent eliminates the need for dedicated alignment components.
2Ease of operation
If a terminal-alignment member is added to facilitate press-fit terminal insertion, then the ease of operation improves, but the manufacturing cost and production time increase
Solution Approach 1:
The guide hole is formed as an integral part of the housing structure, combining the alignment function with the existing housing manufacturing process. This eliminates separate manufacturing steps for producing and assembling terminal-alignment members, reducing both manufacturing cost and assembly time.
Solution Approach 2:
The guide hole is designed with a specific structure that segments the insertion path into guided and unguided portions, facilitating smooth terminal insertion without requiring additional alignment components.
3Reliability
If the distance between connector housing and circuit board is increased, then the reliability of electric connection improves, but the ease of inserting press-fit terminal worsens
Solution Approach 1:
The guide hole acts as an intermediary structure between the connector housing and the circuit board, providing a physical pathway that guides the press-fit terminal through the increased distance. This mediator structure maintains insertion ease despite the larger spacing required for reliable electrical connection.
Solution Approach 2:
The patent replaces the need for mechanical alignment members with a geometric solution - the guide hole's shape and positioning provide the necessary alignment and guidance functions through its structural design rather than through additional mechanical components.
Data Source
AI summary
A circuit connection apparatus has a connector including a housing in which a connection terminal is contained, a positioning guide portion provided therein at an opposite side to an opening portion of the housing, and a press-fit terminal extended from the connection terminal. Moreover, the circuit connection apparatus has a heat sink that includes a guide receipt portion fitted with the positioning guide portion—and an opening to be penetrated by the press-fit terminal and to which the housing is fixed. Furthermore, the circuit connection apparatus has a circuit board that includes a board positioning guide portion and a through-hole to which the press-fit terminal is pressure-bonded and that is fixed to the heat sink. Because the press-fit terminal and the through-hole can accurately be positioned, it is made possible that the reliability is raised and a simple assembly process suppresses the production cost from rising.