Surface Mount Crimp Terminal with Insulation Piercing
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Solution Overview
Problem
Existing surface mount connectors are large, inefficient in terms of space usage on printed circuit boards, lack strain relief, and are not easily compatible with automatic pick and place equipment, and do not provide reliable termination of insulated conductors.
Innovation Solution
A surface mount crimp terminal with a U-shaped cross-section and insulation piercing means, designed for efficient crimping and attachment to printed circuit boards, using a crimping tool to secure insulated conductors with a small footprint and provide strain relief, compatible with automatic pick and place equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two-piece connection system with receptacle and mating tab is used, then reliable electrical connection is achieved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the receptacle and mating tab into a single integrated surface mount crimp terminal. The terminal includes both the body that receives the conductor and the mounting legs that attach to the PCB, eliminating the need for separate components and reducing assembly steps while maintaining reliable electrical connection.
Solution Approach 2:
The single terminal component performs multiple functions: it provides electrical connection, mechanical support, strain relief, and PCB mounting all in one piece. This multi-functional design replaces the two-piece system while achieving the same reliability goals.
2Ease of operation
If large surface mount IDC terminals are used, then insulation displacement connection is achieved, but the footprint area on the PCB increases substantially
Solution Approach 1:
The terminal design optimizes the distribution of its dimensions, making it narrower in the critical footprint direction while maintaining sufficient length for proper crimping and strain relief. This dimensional optimization allows insulation displacement connection with a reduced PCB footprint.
3Reliability
If conventional surface mount terminals are used, then electrical connection is provided, but strain relief on the wire is insufficient
Solution Approach 1:
The terminal integrates both the electrical connection function and the strain relief function into a single component. The body of the terminal provides the crimping action for electrical connection, while the extended structure provides mechanical strain relief, combining previously separate functions.
4Ease of manufacture
If traditional crimp terminals are used, then conductor termination is achieved, but compatibility with automatic pick and place equipment is poor
Solution Approach 1:
The terminal includes a flat top surface that provides a standardized interface for vacuum pickup by automated pick and place equipment. This geometric feature enables automation compatibility while maintaining the traditional crimping function for conductor termination.
5Ease of operation
If pre-stripped conductors are used, then simple insertion is achieved, but additional manual operations are required
Solution Approach 1:
The terminal incorporates insulation piercing means that automatically pierce the insulation and contact the conductor during the crimping process. This self-service feature eliminates the need for separate insulation stripping operations, simplifying the process while maintaining productivity.
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 allows for efficient, reliable, and space-saving termination of insulated conductors on printed circuit boards with enhanced strain relief and compatibility with automatic equipment, ensuring secure and efficient electrical connections.
Implementation Method 1
providing a generally central flat surface area suitable for cooperation with a vacuum nozzle of a pick-and-place machine
Implementation Method 2
Said side walls are capable of being crimped or bent inwardly toward each other and toward said bottom wall to at least partially close or reduce the dimensions of said open side
Data Source
AI summary
A surface mount insulation terminal is formed of flat deformable conductive member to provide a substantially uniform U-shaped cross-section to form a wire-receiving channel. One or more piercing spikes are formed on a bottom wall of the channel and point to an opposing open side through which a conductor may be introduced. Ribs inside the channel provide an interference fit with a conductor introduced into the channel. A crimping tool lowered into engagement with the terminal after it has been soldered to a PCB increasingly deforms the side walls of the terminal inwardly towards each other and towards the bottom wall to enhance the electrical and mechanical properties of the resulting termination.