Press-Fit Terminal Guide Portion for Substrate Alignment
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Solution Overview
Problem
Existing press-fit terminal connection methods face challenges in aligning multiple press-fit terminals with corresponding through holes in a substrate, leading to difficulties in assembly and potential misalignment.
Innovation Solution
Incorporating guide portions on the substrate with tapered surfaces and reduced-hole portions to guide and position the press-fit terminals, reducing insertion resistance and facilitating accurate alignment and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If press-fit terminals are connected to through holes in substrate without guide portions, then the structure is simpler, but positioning accuracy between terminals and through holes deteriorates
Solution Approach 1:
The guide portion acts as an intermediary element between the press-fit terminal and the through hole. It provides a tapered guide surface that receives the tip end of the terminal and guides it into proper alignment with the through hole, thereby improving positioning accuracy without requiring complex external fixtures or alignment mechanisms.
Solution Approach 2:
The guide portion is pre-formed on the substrate before the press-fit terminal is inserted. The tapered guide surface is prepared in advance to receive and guide the terminal tip end, ensuring proper alignment is established before the actual press-fit connection occurs, thus improving positioning accuracy.
2Ease of operation
If multiple press-fit terminals are assembled to substrate without guide portions, then the assembly process is faster, but alignment difficulty increases
Solution Approach 1:
The guide portion serves as a mediator that automatically aligns multiple press-fit terminals with their corresponding through holes during the assembly process. The tapered guide surfaces provide self-aligning features that guide each terminal into correct position, making the assembly process easier while maintaining high alignment accuracy.
Solution Approach 2:
The guide portions on the substrate provide self-aligning functionality that enables multiple press-fit terminals to be automatically positioned correctly during assembly. The tapered guide surfaces work passively to guide the terminals into proper alignment without requiring external alignment tools or complex positioning mechanisms, thereby improving both assembly ease and alignment accuracy.
3Ease of operation
If guide portions with tapered surfaces are added to substrate, then positioning of press-fit terminals is improved, but device complexity increases
Solution Approach 1:
The substrate structure is segmented by adding separate guide portions that are distinct from the through holes and press-fit terminals. Each guide portion is an independent feature with a tapered surface that specifically serves the positioning function, allowing the substrate to provide multiple functions (support, electrical connection, and positioning guidance) without requiring a complete redesign of the entire structure.
Solution Approach 2:
The guide portions act as intermediary structures that mediate between the press-fit terminals and the substrate. The tapered surfaces of the guide portions provide the positioning function without requiring complex external fixtures or modification of the press-fit terminals themselves, thereby improving positioning ease while adding only minimal structural complexity to the substrate.
Data Source
Figure 1~2
Figure 3A~3B
Figure 3C~3D
AI summary
In a control unit having a press-fit structure, a wiring substrate includes: a connected portion to which the press-fit terminal is connected; and a guide portion extending from the wiring substrate around the connected portion. The press-fit terminal includes: a tip end portion; a contact portion adjacent to the tip end portion; and an enlarged portion. The guide portion includes: an opening portion; a guide hole extending from the opening portion to the wiring substrate; a tapered surface formed on an inner side of the opening portion; and a reduced-hole portion formed continuous to the tapered surface . The tip end portion of the press-fit terminal is configured such that the contact portion is positioned with respect to the connected portion while the enlarged portion is guided by the tapered surface and an inner wall of the reduced-hole portion.