Split Solder Terminal for PCB Alignment and Connection
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Solution Overview
Problem
Conventional terminals directly mounted on printed circuit boards face issues such as conductor scratching, conduction failure, terminal misalignment, and deformation due to press-fit and soldering methods, which require alignment adjustments and can lead to unstable electric connections.
Innovation Solution
A terminal design featuring split solder portions, where one portion is press-fit into a through hole with four corners contacting the inner surface for positioning and the other is loosely inserted without contacting the inner surface, eliminating the need for alignment adjustments and ensuring stable electrical connectivity by using solder to secure both portions to the printed circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a press-fit terminal is pressed into a through-hole, then the terminal is fixed to the board, but the conductor on the inner wall of the through-hole is easily scratched causing conduction failure
Solution Approach 1:
The terminal is divided into two distinct portions: a first board connecting portion with a press-fit structure for mechanical fixation, and a second board connecting portion with a loop structure for stable electrical connection. This segmentation allows each portion to perform its specific function optimally without interfering with the other, resolving the contradiction between fixing strength and conduction reliability
Solution Approach 2:
Different portions of the terminal are designed with different structural qualities: the first portion has a press-fit structure optimized for mechanical insertion and fixation, while the second portion has a loop structure optimized for electrical connection stability. This local differentiation allows the terminal to simultaneously achieve strong fixation and reliable conduction without the conductor scratching issue
2Ease of manufacture
If a terminal is pressed from above and held by a jig until soldered, then the terminal can be soldered to the board, but terminal misalignment or deformation occurs requiring alignment adjustment
Solution Approach 1:
The first board connecting portion is designed with a press-fit structure that enables preliminary insertion and positioning of the terminal into the through-hole before soldering. This preliminary action establishes accurate alignment in advance, eliminating the need for alignment adjustment during subsequent soldering operations and preventing terminal deformation
Solution Approach 2:
The press-fit structure acts as an intermediary mechanism between the terminal and the through-hole, providing a self-aligning insertion path that guides the terminal into correct position before soldering. This intermediary structure eliminates the need for external jigs and prevents misalignment and deformation during the manufacturing process
3Reliability
If a terminal is inserted into a through-hole and soldered, then electrical connection is achieved, but alignment adjustment is required due to misalignment
Solution Approach 1:
The terminal is segmented into a press-fit portion for mechanical positioning and a loop portion for electrical connection. This segmentation allows the terminal to be inserted and positioned accurately before soldering, eliminating the need for alignment adjustment and simplifying the manufacturing process while ensuring stable electrical connection
Solution Approach 2:
The press-fit structure provides self-aligning and self-positioning capabilities during insertion, allowing the terminal to automatically achieve correct alignment without external assistance or adjustment. This self-service mechanism eliminates complex alignment adjustment processes while ensuring reliable electrical connection after soldering
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
This design enhances alignment accuracy and stability of the electric connection, preventing deformation and misalignment, and allows for secure attachment without the need for external holding devices, ensuring reliable connectivity and simplified assembly.
Implementation Method 1
spaces between the through holes 8a, 8b and the board connecting portions 6a, 6b are filled with solder 9 for connection with a circuit on the printed circuit board 7
Data Source
AI summary
A terminal has a plurality of split solder portions inserted into through-holes in a printed circuit board. A first split solder portion has a cross-sectional shape such that four corners thereof contact an inner circumferential surface of the through hole for positioning, while a second split solder portion has a cross-sectional shape such that the portion is loosely inserted into the through hole without contacting an inner circumferential surface thereof. The plurality of split solder portions of the terminal are inserted into through holes having substantially equal diameters. The four corners of the first split solder portion contact the inner circumferential surface of the through hole for positioning and holding. The second split solder portion does not contact the inner circumferential surface of the through hole. The through holes are filled with solder to fix the split solder portions therein.