Press-fit Electronic Relay Contacts for Automated PCB Assembly
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Solution Overview
Problem
Existing methods for manufacturing electronic relays are inefficient and prone to mechanical damage due to the need for precise alignment and soldered connections, which limits automated production and increases manufacturing costs, especially as components become more complex and space-constrained.
Innovation Solution
The use of press-fit technology for connecting electrical contacts to a circuit board, eliminating the need for soldering and allowing for automated alignment and connection, with force-receiving sections designed to manage mechanical forces and ensure stable contact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldered connections are used to connect contacts to the circuit board, then electrical connection is achieved, but mechanical forces can damage the soldered joints leading to premature failure
Solution Approach 1:
The patent replaces the soldered mechanical-thermal connection system with a press-fit mechanical connection system. The contacts are pressed directly into the circuit board through a press-fit process, eliminating the need for soldering. This mechanical press-fit connection is more resistant to mechanical forces and vibrations while maintaining electrical conductivity, thereby resolving the contradiction between connection reliability and mechanical strength.
2Manufacturing precision
If contacts are manually aligned and installed at right angles, then proper electrical connection is achieved, but automated production becomes economically unviable
Solution Approach 1:
The patent incorporates alignment features directly into the contact structure during manufacturing, such as angled sections or positioning elements that guide the contact into the correct orientation during the press-fit process. This preliminary preparation of alignment features allows automated systems to achieve proper alignment without complex manual intervention, thereby enabling economical automated production while maintaining manufacturing precision.
3Adaptability or versatility
If more functions are integrated into smaller electronic components, then component efficiency is improved, but the available area on the printed circuit board becomes very limited
Solution Approach 1:
The patent divides the contact structure into multiple functional segments, including angled sections for alignment, press-fit sections for connection, and electrical contact sections. This segmentation allows each part to perform its specific function efficiently within a compact overall structure, enabling higher functionality integration in smaller components without requiring additional circuit board area.
Data Source
AI summary
A base plate for an electronic component, in particular an electronic relay, has a plate-shaped base body, in particular made of plastic, and at least one electrical contact. The electrical contact fully extends through the base body. At one end the electrical contact forms an electrical terminal of the electronic component, in particular of the relay. At another end the electrical contact has an electrically conductive connection section which can be connected to a circuit board without soldering, in particular by being pressed into the circuit board, to form a permanent electrical connection.