Tolerance-Compensating Contact Carrier for PCB Assembly

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Solution Overview

Problem

The issue of 'blurring' during soldering leads to incorrect positioning of contact carriers on printed circuit boards, resulting in manufacturing inefficiencies and potential electrical disconnects.

Innovation Solution

Incorporating a tolerance compensation section in the contact arm, which is elastically or plastically deformable, to compensate for positional errors caused by blurring, allowing for correct alignment and secure electrical connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional soldering processes are used to assemble contact carriers on printed circuit boards, then assembly density and cost-effectiveness are improved, but positioning accuracy deteriorates due to blurring during soldering

Engineering Contradiction:

Improveassembly densityVSAvoidpositioning accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The contact arm's material properties are changed to be elastically or plastically deformable, allowing it to adapt to positioning deviations caused by soldering blurring. This parameter change in material behavior enables the contact arm to compensate for position errors without requiring higher assembly precision.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The deformable contact arm acts as a pre-designed compensation mechanism that anticipates and cushions against positioning errors from soldering blurring. By incorporating this tolerance compensation section beforehand, the system prevents positioning errors from affecting electrical connection reliability.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Manufacturing precision

If rigid contact arms are used to ensure precise positioning, then positioning accuracy is improved, but adaptability to soldering deviations deteriorates

Engineering Contradiction:

Improvepositioning accuracyVSAvoidtolerance to positioning errors

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The contact arm transitions from a rigid, fixed-geometry component to a dynamic component that can elastically or plastically deform. This dynamic behavior allows the contact arm to adapt its shape and position after soldering, compensating for blurring-induced deviations while maintaining electrical connection.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The mechanical properties of the contact arm are changed from rigid to deformable, enabling it to absorb positioning errors through elastic or plastic deformation. This parameter change in material behavior provides adaptability to soldering deviations.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If tolerance compensation mechanisms are added to compensate for soldering blurring, then positioning accuracy is improved, but device complexity increases

Engineering Contradiction:

Improvepositioning accuracyVSAvoidstructural complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The tolerance compensation function is merged into the contact arm itself rather than being a separate mechanism. The contact arm's deformable structure integrates both the electrical connection function and the positioning compensation function, avoiding additional complex components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The contact arm's deformable structure enables self-compensation of positioning errors without requiring external adjustment mechanisms or additional components. The material's elastic or plastic properties allow it to automatically adapt to soldering deviations.

Inventive Principle:

Principle #25Self-service

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 tolerance compensation section effectively increases manufacturing yield by ensuring accurate positioning and secure electrical connections, reducing space requirements and manufacturing complexities.

Implementation Method 1

the contact arm having a tolerance compensation section and a contact formed on the tolerance compensation section for making electrical contact with the electrical contact includes a contact surface. This achieves the technical advantage that the tolerance compensation section compensates for incorrect positioning by blurring.

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentEP2959546B1Contact carrier with a tolerance-compensating portion

Publication Date: 2017.03.29 PHOENIX CONTACT GMBH & CO KG

AI summary

The invention relates to a contact carrier (100) comprising an electrical contact (128) and a contact arm (136) which is connected to the electrical contact (128) in an electrically conducting manner. The contact arm (136) comprises a tolerance-compensating portion (138) and a contact base (132) formed on the tolerance-compensating portion (138) for electrically contacting the electrical contact (128) with a contact surface.