Protective Sleeve for Electrical Pins Using Insulating Clips
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Solution Overview
Problem
Electrical components with protruding pins are prone to short circuits due to dust, solder flux, and moisture accumulation, leading to potential device failure and catastrophic circuit board issues, necessitating effective protection and insulation.
Innovation Solution
A protective sleeve structure with non-conductive materials and tapered clips that clip over pins, providing electrical insulation, preventing contaminant accumulation, and maintaining pin alignment during soldering processes, while being easy to manufacture and employ.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pins are exposed to environment for electrical connection, then electrical connectivity is achieved, but pins are susceptible to short circuits from dust, solder flux, and moisture accumulation
Solution Approach 1:
The patent applies this principle by using a protective boot (a flexible shell structure) that covers each pin. The boot is made of non-conductive material and includes a tapered portion that flexes during insertion to accommodate the pin, then retains the pin in place. This flexible shell protects the pin from dust, solder flux, and moisture while maintaining electrical connectivity through the non-conductive material's insulation properties.
Solution Approach 2:
The patent applies this principle by introducing a protective boot as an intermediary element between the pin and the environment. The boot acts as a mediator that allows the pin to perform its electrical function while simultaneously protecting it from harmful contaminants. The non-conductive boot material provides electrical insulation between adjacent pins, preventing short circuits while the tapered design allows easy insertion and retention.
2Reliability
If protective covering is added to pins, then protection from contaminants and electrical insulation is improved, but device complexity increases
Solution Approach 1:
The patent applies this principle by dividing the protective structure into individual boots for each pin rather than using a single complex covering for all pins. Each boot is a simple, standalone component with a tapered portion and retention features. This segmentation allows for easy manufacturing, assembly, and maintenance while providing effective protection for each pin individually, thus reducing overall device complexity compared to a unified protective structure.
Solution Approach 2:
The patent uses simple flexible boot structures that can be easily molded and assembled. Each boot is a thin-walled non-conductive component with a tapered portion that flexes during insertion. This simple shell design provides comprehensive protection (contaminant barrier and electrical insulation) without requiring complex mechanisms, thereby improving reliability while minimizing the increase in device complexity.
3Manufacturing precision
If protective boots with clips are used to retain pins, then pin alignment and stability are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies this principle by combining multiple functions into a single boot component: the tapered portion provides alignment guidance during insertion, the retention clips hold the pin securely in place, and the non-conductive material provides electrical insulation. By merging these functions into one integrated part rather than using separate components, the design achieves precise pin alignment and stability while actually simplifying manufacturing and assembly processes.
Solution Approach 2:
The boot is designed as a flexible thin-walled non-conductive structure that can be easily molded using standard injection molding techniques. The tapered portion and retention clips are formed as integral features of the boot during a single molding process. This approach achieves precise pin alignment through the tapered guidance feature while maintaining ease of manufacture through a simple, one-step production process without requiring complex assembly operations.
Data Source
AI summary
A sleeve structure includes an electrically insulating protective sleeve having clips that retain and capture component pins and regulate a mounting distance of the electrical component from a wiring structure. A method of component wiring assembly is also included.