Removable Retainer for Electrical Contacts Using Segmented Holders
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Solution Overview
Problem
Current technologies for connecting electrical contacts to printed circuit boards either require bulky blocks for soldering, leading to reduced PCB space, or use press-fit methods that are costly and limited in current-carrying capacity, and lack reusable and adjustable solutions for individual pin connections.
Innovation Solution
A removable device with a rigid holding element and elastic sprung blades that allows precise positioning and retention of electrical contacts during soldering, enabling flexible and precise placement without permanent blocks, and allowing for reuse by compensating for size variations in contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a permanent block is used to hold electrical contacts during soldering, then the contacts are securely retained, but the effective area on the PCB is reduced due to shadowing
Solution Approach 1:
The permanent block is segmented into individual removable holders, each capable of holding one or few electrical contacts. This segmentation allows the holders to be positioned only where needed around the PCB perimeter, minimizing shadowing while providing secure retention during soldering. The holders can be removed after soldering, completely clearing the PCB surface.
Solution Approach 2:
A removable holder acts as an intermediary device between the electrical contact and the PCB during the soldering process. It provides temporary support and retention only when needed, then is removed to eliminate shadowing. This intermediary approach allows secure contact retention during soldering while maintaining maximum PCB effective area after the process.
2Manufacturing precision
If press-fit technology is used to position electrical contacts individually, then precision is improved, but the ability to withstand large currents is reduced
Solution Approach 1:
The electrical contacts are preliminarily positioned with high precision using press-fit technology into the removable holders, which are then attached to the PCB perimeter. This allows precise positioning during assembly while the final current-carrying connection is established through soldering, which provides the necessary strength for large currents. The preliminary press-fit ensures accurate placement before the stronger soldered connection is made.
3Area of stationary object
If a removable holder is used to increase PCB effective space, then the available area is improved, but the retaining force may rip out the soldered pin during removal
Solution Approach 1:
The removable holder incorporates an elastic element that provides dynamic, adjustable retaining force. The elastic element can be compressed to increase retention strength during soldering, then relaxed to allow easy removal after soldering. This dynamic adjustment of retaining force ensures strong contact retention during the soldering process while enabling safe removal without damaging the soldered connection, all while maintaining maximum PCB effective space.
4Reliability
If friction-based retention in tubular housings is used, then pins are held during soldering, but the device cannot be reused due to wear
Solution Approach 1:
The retention mechanism changes from static friction-based retention to dynamic elastic-based retention. The elastic element can be compressed and relaxed repeatedly without significant wear, allowing the holder to be reused multiple times. When compressed, the elastic element provides strong retaining force to hold pins during soldering; when relaxed, it allows easy insertion and removal of pins. This parameter change from friction to elastic force enables both reliable retention during soldering and long-term reusability.
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 sturdy connections with increased PCB layout density, reduced waste, and improved precision, enabling closer placement of components and efficient reflow soldering processes while being reusable and cost-effective.
Implementation Method 1
an elastic element for retaining said electrical contacts in the holding element including a plurality of sprung blades
Implementation Method 2
a rigid element for holding electrical contacts including a plurality of housings that are configured to accept said electrical contacts
Data Source
AI summary
A removable device for retaining electrical contacts, having: a rigid element for holding electrical contacts including a plurality of housings that are configured to accept the electrical contacts, the lateral walls of the holding element that are adjacent to the housings having a plurality of openings that each lead into one housing of the plurality of housings of the holding element; and an elastic element for retaining the electrical contacts in the holding element including a plurality of sprung blades that are arranged facing the openings leading into the housings of the rigid holding element so as to retain the electrical contacts in the housings of the holding element. The invention further relates to a soldering method implementing such a device.