Surface Mount Connector With Lead Slots And Spring Contacts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The removal and replacement of electrical components in electrical systems are difficult and often damage the components or the circuit board, with solder joints prone to failure due to movement, necessitating a reliable electrical connection.
Innovation Solution
An electrical connector design featuring a housing with lead slots and guide tabs that securely engage leads of electrical components, allowing for quick connection and disconnection without soldering, using contacts with solder pads for secure mounting to the circuit board and spring beams for reliable electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If soldering is used to connect electrical components to circuit board, then electrical connection is established, but removal and replacement becomes difficult and may damage components or circuit board
Solution Approach 1:
The electrical connection system is divided into separate components: a circuit board with soldered contacts, and removable electrical components with leads. This segmentation allows the circuit board to remain fixed while components can be easily removed and replaced without damaging the board, resolving the contradiction between ease of operation and reliability.
Solution Approach 2:
The patent introduces an intermediate connection mechanism where electrical components connect to the circuit board through receptacles and contacts rather than direct soldering. This intermediary connection allows for easy removal and replacement while maintaining reliable electrical connection, eliminating the need to damage the circuit board during component replacement.
2Reliability
If solder joints are used to connect electrical component leads to circuit board, then electrical connection is established, but solder joints may be damaged or break over time due to movement
Solution Approach 1:
The connection system is segmented into rigid soldered contacts on the circuit board and flexible receptacles with spring contacts. This segmentation allows the spring contacts to absorb movement and stress, protecting the solder joints from damage while maintaining reliable electrical connection over extended periods.
Solution Approach 2:
The patent changes the mechanical properties of the connection interface by using spring-loaded receptacles with flexible contacts instead of rigid solder joints. This parameter change allows the connection to accommodate movement and stress, significantly extending the service life of the electrical connection while maintaining reliability.
3Reliability
If direct soldering of component leads to circuit board is used, then electrical connection is established, but the connection process becomes complex and time-consuming
Solution Approach 1:
The assembly process is segmented into two stages: soldering the receptacles to the circuit board (done once), and then plugging in electrical components (repeated as needed). This segmentation eliminates the need to solder each component individually, dramatically increasing assembly speed while maintaining reliable electrical connections.
Solution Approach 2:
The receptacles are pre-soldered to the circuit board during manufacturing, creating a ready-to-use connection interface. This preliminary action allows electrical components to be quickly plugged in without requiring soldering operations during assembly, significantly improving productivity while ensuring reliable connections.
4Reliability
If soldering process is used to attach electrical components, then electrical connection is established, but the process may damage the electrical component and circuit board
Solution Approach 1:
The manufacturing process is segmented so that only the receptacles require soldering to the circuit board, while the electrical components themselves are never subjected to soldering heat. This segmentation protects component integrity during assembly while still establishing reliable electrical connections through the receptacle-contact interface.
Solution Approach 2:
The receptacle serves as an intermediary that protects electrical components from direct exposure to the soldering process. The components connect to the receptacles through simple mechanical insertion rather than soldering, preserving component integrity while maintaining reliable electrical connection.
Data Source
AI summary
An electrical connector includes a housing having contact chambers between a top and a bottom configured to be mounted to a circuit board. A rear wall of the housing includes lead slots open at the top to receive leads of an electrical component. The electrical connector includes a cover coupled to the top of the housing above the leads. The electrical connector includes contacts received in corresponding contact chambers. Each contact includes a base having a solder pad at a bottom configured to be soldered to a circuit board conductor of the circuit board. Each contact includes contact beams extending from the base to form a socket proximate to the top of the housing that receives the lead of the electrical component from above to electrically connect to the lead of the electrical component.