Press-Fit Heating Element Connector Assembly
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Solution Overview
Problem
Current heating element assemblies for drug delivery systems are expensive and difficult to construct due to the use of soldered connections between conductive members and circuit boards.
Innovation Solution
A heating element connector assembly with a simplified design using mechanical connections, featuring an insulative rectangular frame with conductive terminals and deformable contact portions that connect conductive strips to the terminals without soldering, allowing for easy mounting to a circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldered connections are used to connect conductive terminals to circuit boards, then electrical continuity is achieved, but manufacturing cost increases and construction becomes difficult
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical joining) with a mechanical press-fit system. Conductive terminals with compliant pin tail portions are inserted into holes in the circuit board and mechanically secured, eliminating the need for soldering while maintaining electrical continuity through direct metal-to-hole contact.
Solution Approach 2:
The compliant pin tail portions act as intermediaries between the conductive terminals and the circuit board holes. These pins provide a flexible mechanical connection that accommodates manufacturing tolerances and ensures reliable electrical contact without requiring precise alignment or soldering.
2Reliability
If soldered connections are used to connect conductive terminals to circuit boards, then electrical continuity is achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical joining) with a mechanical press-fit system. Conductive terminals with compliant pin tail portions are inserted into holes in the circuit board and mechanically secured, eliminating the need for soldering while maintaining electrical continuity through direct metal-to-hole contact.
Solution Approach 2:
The compliant pin tail portions are designed to self-align and self-secure within the circuit board holes through their inherent flexibility. The pins deform elastically during insertion and maintain constant contact pressure, providing a self-adjusting connection that reduces manufacturing complexity and cost.
3Reliability
If deformable contact portions are used to connect conductive strips to terminals, then mechanical connection reliability is improved, but terminal complexity increases
Solution Approach 1:
The contact portions of the terminals are designed to change their physical state from undeformed to deformed during assembly. The contact portions are initially in a relaxed state for easy insertion, then deformed using a simple tool to create a locked connection with the conductive strips, providing reliable mechanical attachment through controlled deformation.
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
The solution provides a reliable, cost-effective electrical contact structure that reduces manufacturing costs and simplifies the construction of heating element assemblies, enabling efficient drug vaporization in drug delivery systems.
Implementation Method 1
The terminals further have contact portions that rise up from the body portions. The contact portions are best described as deformable lugs, and to facilitate their deforming, the lugs may include center notches.
Data Source
AI summary
An improved heating element connector assembly includes an insulative, rectangular frame with a central opening and a plurality of conductive terminals which are press fit into openings in the frame. The terminals are spaced apart from each other lengthwise of two opposing sidewalls of the frame, and pairs of terminals are aligned with each other between the two sidewalls. A plurality of conductive strips extend across the frame opening to interconnect the pairs of terminals together. The terminals include compliant pin tail portions for receipt by corresponding holes formed in a circuit board of the assembly and deformable head portions for crimping onto the conductive strips.