Terminal Cross-Section Adjustment for Uniform Current Flow
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Solution Overview
Problem
In electronic components with terminals inserted into through holes in a substrate, differences in terminal lengths and cross-sectional areas lead to variations in electrical resistance, causing uneven current flow through the terminals, which complicates the design and operation of the components.
Innovation Solution
The design includes terminals with varying lengths and cross-sectional areas, where the length of one terminal is longer than the other, and the cross-sectional area of the terminal's end is larger than the other, ensuring equal electrical resistance and consistent current flow by matching the contact resistances at the joined portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminals with different lengths and cross-sectional areas are used, then current flow uniformity is improved, but device complexity increases
Solution Approach 1:
The patent applies local quality by varying the cross-sectional area of terminals at specific locations (insertion portions) while keeping other portions uniform. This allows different terminals to have different electrical resistances tailored to their specific insertion depths, achieving uniform current flow without making the entire terminal structure complex. Each terminal's insertion portion is locally modified to compensate for depth variations.
Solution Approach 2:
The patent changes the physical parameter of cross-sectional area to control electrical resistance. By adjusting the cross-sectional area of terminal insertion portions, the patent creates intentional resistance differences that compensate for variations in insertion depth, thereby achieving uniform current distribution across all terminals despite their different lengths.
2Reliability
If terminals with varying cross-sectional areas are designed, then contact resistance matching is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-designing the specific cross-sectional area values needed for each terminal's insertion portion. This allows the manufacturing process to target specific predetermined dimensions, making it easier to control precision. The design phase incorporates the resistance compensation requirements, so manufacturing only needs to achieve the specified dimensions rather than adjusting during assembly.
3Adaptability or versatility
If terminal lengths are made different to accommodate varying insertion depths, then adaptability is improved, but electrical resistance variation worsens
Solution Approach 1:
The patent applies local quality by modifying only the insertion portions of terminals rather than changing the entire terminal structure. This allows terminals to have different lengths for accommodating varying insertion depths while keeping the non-insertion portions uniform. The local modification of cross-sectional area at insertion portions creates the necessary resistance differences to compensate for length variations.
Data Source
AI summary
An electronic component includes: a first terminal that is inserted into a first through hole in a substrate; and a second terminal that is inserted into a second through hole in the substrate, wherein a length of the first terminal from a first end that is inserted into the first through hole to a second end is longer than a length of the second terminal from a third end that is inserted into the second through hole to a fourth end, and a cross sectional area of a portion of the first terminal positioned on a side of the second end with respect to a first joined portion is larger than a cross sectional area of a portion of the second terminal positioned on a side of the fourth end with respect to a second joined portion.