Press-Fit Connector Alignment in Compact Heat Sink Assemblies
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Solution Overview
Problem
The assembly of circuit connection devices is hindered by potential collisions between press-fit terminals and guide through holes due to misalignment, leading to buckling and decreased quality, and increasing the device size to prevent such collisions results in unnecessary downsizing.
Innovation Solution
A circuit connection device with a terminal alignment member and heat sink design that includes positioning protrusions and recesses for precise alignment, allowing for guided insertion of press-fit terminals into terminal through holes while optimizing device size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the radius of openings of the guide through holes is made larger to prevent collision, then the press-fit terminals can be inserted more easily, but the disposition interval of the guide through holes must be made larger, which increases the device size
Solution Approach 1:
The insertion guide hole is designed with an inclined and expanding shape that preliminarily guides the press-fit terminal into proper alignment before the terminal reaches the guide through hole. This preliminary guiding action prevents collision and enables easy insertion without requiring a larger opening radius, thereby maintaining compact device dimensions.
2Ease of operation
If the angle of inclination of the insertion guide hole is made smaller to prevent buckling, then the press-fit terminals can be inserted more smoothly, but the thickness of the terminal alignment member must be made larger, which increases the device size
Solution Approach 1:
The insertion guide hole provides preliminary alignment and guidance at a smaller angle, gradually directing the press-fit terminal into the correct position. This preliminary action prevents buckling during insertion while maintaining a compact thickness of the terminal alignment member, avoiding the need to increase device size.
3Manufacturing precision
If positioning protrusions and recesses are added to ensure precise alignment, then the assemblability is improved, but the device complexity increases
Solution Approach 1:
Positioning protrusions and recesses are introduced as intermediary alignment features between the connector and circuit board. These features act as mediators that automatically guide components into precise alignment during assembly, improving manufacturing precision while adding minimal structural complexity through simple geometric forms.
Data Source
AI summary
A circuit connection device includes a connector having press-fit terminals, a circuit board that has terminal through holes formed, and the press-fit terminals are press-inserted into the terminal through holes, a terminal alignment member having a terminal guide that has guide through holes formed, where the guide through holes guide the press-fit terminals towards the terminal through holes, and a heat sink that has an opening which houses the terminal guide on an inside. First positioning protrusions are formed on one of the connector or the heat sink, and first positioning recesses are formed on the other thereof. Second positioning protrusions are formed on one of the circuit board or the terminal alignment member, and second positioning recesses are formed on the other thereof. Third positioning protrusions are formed on one of the heat sink or the terminal alignment member, and third positioning recesses are formed on the other thereof.