Spring Barb Direct Contact Device for PCB Conductor Fastening
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Solution Overview
Problem
Existing methods for electrical contact between a circuit board and conductors, such as screwing, soldering, and press-in technologies, face issues like degradation over time, complexity, high material costs, and increased electrical resistance, making them inefficient and prone to errors.
Innovation Solution
A direct contacting device with a conductor receptacle, a spring barb, and a spacer element that allows for mechanical and electrical connection without tools, using a spring barb to clamp the conductor against the circuit board, ensuring reliable contact with minimal components and low volume resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screwing is used to fasten the conductor, then the conductor can be securely fastened, but the manufacturing complexity increases and the risk of manufacturing defects increases
Solution Approach 1:
The invention extracts the fastening function from the conductor itself and transfers it to a separate clamping element. The clamping element is pre-formed with clamping arms that engage with the conductor, separating the fastening mechanism from the conductor and simplifying the overall assembly process while maintaining secure fastening.
Solution Approach 2:
The clamping element acts as an intermediary between the conductor and the mounting surface. Instead of directly screwing the conductor to the surface, the clamping element mediates the connection, providing a simplified interface that reduces manufacturing complexity and defect risk.
2Reliability
If soldering is used to create permanent connection, then electrical contact is established, but heat is introduced causing premature aging of components
Solution Approach 1:
The invention replaces the thermal soldering process with a mechanical clamping system. The clamping element mechanically secures the conductor to the mounting surface through clamping arms, eliminating the need for heat-intensive soldering while maintaining reliable electrical contact through direct mechanical pressure and contact.
3Reliability
If direct pressure spring is used for electrical contact, then contact is established, but the spring must be pushed back with a tool requiring additional steps
Solution Approach 1:
The clamping arms are pre-formed in the clamping element with the correct geometry and elasticity. This preliminary configuration allows the clamping element to automatically engage and clamp the conductor upon insertion, eliminating the need for post-insertion tool operations to activate the spring mechanism.
Solution Approach 2:
The clamping element is designed to self-activate upon insertion. The elastic clamping arms automatically engage the conductor and apply clamping force without requiring external tool intervention, making the assembly process simpler and more intuitive.
4Ease of operation
If rigid conductors are inserted directly without stretching spring, then insertion is simplified, but only rigid conductors can be used limiting versatility
Solution Approach 1:
The clamping element is designed with adjustable clamping force parameters and geometric flexibility. The clamping arms can adapt their shape and pressure to accommodate different conductor types (rigid, flexible, stranded, solid), allowing simple insertion while maintaining versatility across various conductor configurations.
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 solution provides a strong, reliable, and efficient electrical connection with reduced heat stress and power loss, allowing for easy assembly and maintaining contact even as the conductor material deforms, thus extending the lifespan of components.
Implementation Method 1
the first spring barb, when inserted into the opening, springs in with a first extension in an insertion position and, after being pushed through the opening into a fixing position, springs out with a second, larger extension
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a direct contacting device (101, 201) for fastening a conductor (113) on a circuit board (106) and placing the conductor in electrical contact with the circuit board. The circuit board has an opening (109, 209), which extends completely through the circuit board, and a contacting surface, which is associated with said opening. The direct contacting device comprises a conductor receptacle (103, 203), a first spring barb (107, 207) and a spacer (105, 211). The spacer connects the conductor receptacle (103, 203) and the first spring barb (107, 207) at a distance in accordance with the thickness of the circuit board (106) at the opening (109, 209). While being pushed into the opening (109, 209), the first spring barb (107, 207) compresses into a push-in position with a first extent, and after being pushed through the opening (109, 209), the first spring barb rebounds into a fastening position with a second, larger extent, such that the spacer (105, 211) is arranged in the opening and the conductor inserted into the conductor receptacle is clamped against the circuit board and is placed in electrical contact with the contacting surface.