Press-Fit Terminal Structure for Lower Insertion Force

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Solution Overview

Problem

Conventional press fit terminals experience reduced contact area and stability due to point contact with circuit boards, leading to inadequate connection stability and high insertion force requirements.

Innovation Solution

The design incorporates an assembling portion with arc-shaped outer surfaces and curve-shaped inner surfaces, featuring a connecting portion with bending portions and an indentation, which increases contact area and reduces insertion force by allowing the side walls to be squeezed and deformed to fit snugly into the circuit board's through hole, enhancing connection stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the conventional press fit terminal uses a middle portion structure, then the device complexity is reduced, but the contact area is insufficient and connection stability is affected

Engineering Contradiction:

Improveconnection stabilityVSAvoidcontact area

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The contact structure is segmented into multiple contact portions (first contact portion and second contact portion) instead of a single middle portion. Each contact portion has arc-shaped outer surfaces that contact the inner arc surface of the soldering hole, distributing the contact area and improving connection stability while maintaining structural simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The contact structure transitions from a single-point or single-area contact (middle portion) to a multi-area contact configuration. The first and second contact portions extend the contact area in the radial direction, creating a ring-shaped contact zone that increases the effective contact area with the soldering hole inner surface.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of operation

If the press fit terminal uses a conventional structure, then the ease of manufacture is maintained, but the insertion force is high

Engineering Contradiction:

Improveinsertion easeVSAvoidinsertion force

Core Design Contradiction:

Ease of operationVSForce

Solution Approach 1:

The geometry parameters of the contact portions are optimized with arc-shaped outer surfaces that match the inner arc surface of the soldering hole. This geometric parameter change reduces stress concentration and distributes insertion force more evenly, lowering the peak insertion force required while maintaining manufacturability through standard stamping processes.

Inventive Principle:

Principle #35Parameter changes

3Area of stationary object

If the conventional press fit terminal uses a middle portion design, then the device complexity is low, but the contact area is insufficient

Engineering Contradiction:

Improvecontact areaVSAvoidstructure complexity

Core Design Contradiction:

Area of stationary objectVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The contact portions serve multiple functions: they provide electrical connection, distribute mechanical stress, and ensure proper positioning within the soldering hole. This multi-functionality is achieved through the arc-shaped geometry that simultaneously optimizes electrical contact and mechanical fit without requiring additional complex components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 enhanced contact area and reduced insertion force improve the connection stability and ease of assembly, ensuring a secure and efficient electrical connection with the circuit board.

Implementation Method 1

When two elastic portions of the common press fit terminal are squeezed, the two elastic portions of the common press fit terminal are elastically contracted

Methodology Applied

Scientific EffectElastic contraction: Elasticity

Implementation Method 2

The two outer surfaces of the two side walls are tightly attached to an interior surface of an inner wall of the through hole

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 3

allowing the side walls to be squeezed and deformed to fit snugly into the circuit board's through hole

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS20250015518A1Press fit terminal

Publication Date: 2025.01.09 CHENG UEI PRECISION IND CO LTD

AI summary

A press fit terminal includes an assembling portion, an insertion portion and a fastening portion. The assembling portion has two side walls and a connecting portion. The two side walls are disposed to two opposite sides of the assembling portion, respectively. The connecting portion is disposed in a middle of the assembling portion. The connecting portion is connected between the two side walls. Each side wall has an outer surface and an inner surface. The two outer surfaces of the two side walls are shown as two arc shapes. The two inner surfaces of the two side walls are shown as two curve surfaces. The insertion portion is connected with two ends of the two side walls of the assembling portion. The fastening portion is connected with the other two ends of the two side walls of the assembling portion.