Press-Fit Fastener Geometry for Single-Motion PCB Assembly

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Solution Overview

Problem

Existing fasteners, such as screws, require complex installation processes and can lead to higher failure rates due to cross-threading and stripping, occupying valuable space on circuit boards, and may not provide efficient electrical connections.

Innovation Solution

Press-fit fasteners with deformable geometry and eyelet design that are inserted into corresponding holes in a single motion, providing mechanical and electrical connections while minimizing board space usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If screws are used to secure components, then mechanical connection is achieved, but installation complexity increases and failure rate increases

Engineering Contradiction:

Improvemechanical connectionVSAvoidinstallation process

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent extracts the threading function from the fastener itself, using a smooth cylindrical post that relies on friction and interference fit rather than threads. This eliminates the complex threading operation during installation while maintaining secure mechanical connection through the press-fit mechanism.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical threading system with a press-fit system based on elastic deformation and friction. The fastener body deforms elastically during insertion to create interference fit with the hole walls, providing secure attachment without requiring threaded engagement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If screws are used to secure components, then mechanical connection is achieved, but failure rate increases due to cross-threading and stripping

Engineering Contradiction:

Improvemechanical connectionVSAvoidfailure rate

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent removes the threading element entirely from the fastener design, eliminating the sources of cross-threading and stripping failures. The smooth cylindrical post with controlled interference fit provides a more reliable connection that cannot suffer from thread-related failure modes.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the engagement mechanism from threaded interference to radial interference fit. By controlling the diameter of the post relative to the hole diameter and the material properties, the design achieves reliable mechanical connection through elastic deformation and friction without the failure modes associated with threading.

Inventive Principle:

Principle #35Parameter changes

3Strength

If traditional fasteners are used, then components are secured, but board space is occupied

Engineering Contradiction:

Improvesecuring capabilityVSAvoidboard space

Core Design Contradiction:

StrengthVSArea of stationary object

Solution Approach 1:

The patent uses a simple cylindrical geometry that can be easily replicated and arranged in compact patterns on the circuit board. The minimal footprint of each fastener allows for denser placement of components and interconnections, increasing board density without compromising securing capability.

Inventive Principle:

Principle #26Copying

4Productivity

If press-fit fasteners with deformable geometry are used, then assembly speed increases, but manufacturing precision requirements increase

Engineering Contradiction:

Improveassembly speedVSAvoidhole alignment and fit

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent employs elastic deformation of the fastener body during insertion to accommodate minor variations in hole positioning and size. The material's elastic properties allow the fastener to deform during press-fit installation and then recover, providing tolerance compensation that reduces manufacturing precision requirements while maintaining assembly speed.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Facilitates faster assembly, reduces failure rates, increases board density, and enables efficient electrical connections through a reliable joint with reduced space occupation.

Implementation Method 1

The upper and lower insertable portions of the press-fit fastener can be configured to be compressed when inserted into the first and second holes so as to exert force on the first and second holes

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

The press-fit fastener can have a deformable geometry configured to generate outward force on each of the first and second holes

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS12581588B2Press-fit fasteners for securing components together

Publication Date: 2026.03.17 TESLA INC

AI summary

Press-fit fasteners for securing components together are provided. In one aspect, an electronic system assembly includes a first component comprising a first hole, a second component comprising a second hole, and a press-fit fastener configured to be inserted into the first hole and the second hole in a single motion. The press-fit fastener is configured to at least contribute to securing the second component to the first component after insertion into the first and second holes. Related press-fit fasteners and methods of manufacture are disclosed.