Terminal Cage Assembly for Secure Wire-to-Pin Connections
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Solution Overview
Problem
Electronic devices, such as HVAC control panels, are prone to electrostatic discharge (ESD) events, which can damage sensitive components, and existing solutions do not adequately address the ease of use, assembly, and reliability of these devices.
Innovation Solution
The electronic device incorporates a printed wiring assembly (PWA) with a ground plane, a conductive extender or connector, and a spacer to provide ESD protection by grounding the metal backing of electronic components and maintaining electrical connections while allowing for double-sided component placement and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional wiring assembly is used without a cage structure, then the assembly process is simpler, but the wire can become dislodged and electrical connections become unreliable
Solution Approach 1:
The patent implements a cage structure with multiple portions (first portion, second portion, third portion) that are nested together to form a complete terminal assembly. The wire is positioned within the cage, with the first portion securing the wire, the second portion receiving the pin, and the third portion providing additional support. This nested configuration ensures the wire remains securely held while maintaining organized assembly.
2Reliability
If wires are secured tightly to prevent dislodging, then connection reliability improves, but the assembly process becomes more difficult and time-consuming
Solution Approach 1:
The terminal assembly is divided into distinct segmented portions: a first portion for securing the wire, a second portion for receiving the pin, and a third portion for additional support. This segmentation allows each portion to be independently formed and positioned, simplifying the overall assembly process while ensuring reliable wire securing through the coordinated action of multiple specialized components.
3Ease of operation
If the cage structure includes multiple portions for securing wires, then wire management and connection reliability improve, but the device complexity increases
Solution Approach 1:
The patent combines multiple functional portions (first portion for wire securing, second portion for pin reception, third portion for support) into a single integrated cage structure. This merging of functions into one cohesive component simplifies wire management during assembly while maintaining the reliability benefits of multiple securing points, avoiding the need for separate discrete components for each function.
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 effectively protects electronic devices from ESD events, enhances assembly ease, and improves reliability by ensuring secure electrical connections and efficient heat management.
Implementation Method 1
The screw may engage the first portion of the cage and may be configured to generate a force on a wire to secure the wire relative to the first portion of the cage
Implementation Method 2
The second portion of the cage may include one or more flanges configured to receive a corresponding one of the one or more pins extending from the PCB
Data Source
AI summary
A terminal assembly for use with an electronic device may include a first portion for secure a wire and a second portion for receiving a pin of an electronic device. The first portion and the second portion may be configured to electrically connect the pin to the wire.