Deformable Push-Pin Connector for Solder-Free PCB Attachment

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Solution Overview

Problem

Existing methods for fastening electrical components, such as battery cells and printed circuit board assemblies, often require welding or soldering, which are time-consuming and costly, and do not efficiently establish electrical connections.

Innovation Solution

A push-pin connector with an elastically deformable head that inserts into a socket on a printed circuit board assembly, using elastic deformation to create a mechanical and electrical connection, eliminating the need for welding or soldering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding or soldering is used to fasten electrical components, then reliable electrical connection is achieved, but manufacturing time and cost increase

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces thermal joining processes (welding/soldering) with a mechanical push-pin insertion system. The deformable head mechanically engages with the socket through elastic deformation, providing both mechanical fastening and electrical connection simultaneously, eliminating the need for separate welding operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The push-pin connector performs multiple functions in a single operation: it provides mechanical fastening to secure the battery cell to the PCB assembly and simultaneously establishes electrical connection through the conductive deformable head. This multi-functionality eliminates the need for separate welding steps for both mechanical and electrical joining.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If welding or soldering is used to establish electrical connections, then reliable conductivity is achieved, but manufacturing cost increases

Engineering Contradiction:

Improveelectrical conductivityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the mechanical fastening function and electrical connection function into a single integrated push-pin component. The deformable head simultaneously provides structural support for mechanical attachment and conductive path for electrical connection, reducing the number of components and assembly steps required.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention substitutes expensive thermal joining processes (welding/soldering) with a simpler mechanical insertion process. The push-pin is inserted into the socket and retained through elastic deformation, providing reliable electrical connection without the equipment, material, and labor costs associated with welding or soldering operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If traditional fastening methods are used, then secure mechanical attachment is achieved, but electrical connection efficiency decreases

Engineering Contradiction:

Improvemechanical attachment strengthVSAvoidelectrical connection efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The push-pin connector is designed to perform both mechanical fastening and electrical connection functions simultaneously. The deformable head provides structural integrity for secure attachment while maintaining electrical conductivity, eliminating the need for separate mechanical fasteners and electrical connectors.

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 push-pin connector provides a fast, cost-effective, and reliable electrical connection by using elastic deformation to secure the connector to the board assembly, reducing manufacturing time and costs while ensuring effective conductivity.

Implementation Method 1

elastic deformation of the head causes the connector to press against the receiver to retain the connector and the receiver together

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

the first deformable wall and the second deformable wall are resiliently biased toward the undeformed condition to press outwardly relative the central longitudinal axis

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Data Source

PatentUS12506285B2Electrical push-pin connector

Publication Date: 2025.12.23 MILWAUKEE ELECTRIC TOOL CORP

AI summary

An electrical system includes a conductor configured to carry energy from an electrical power supply, a receiver configured to output energy to an electrical component, and a connector electrically and mechanically connecting the conductor and the receiver. The connector includes a base and a head extending from the base along a longitudinal axis. The head includes a void defined therein by a radially inner surface and further includes a radially outer surface. At least a portion of the radially outer surface is curved about the longitudinal axis. The head is insertable into the receiver, and elastic deformation of the head causes the connector to press against the receiver to retain the connector and the receiver together.