Two-Zone Wire Connector for Permanent PCB Wire Termination
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Solution Overview
Problem
Existing wire-connecting solutions for metallic wires to printed circuit boards or electrically conductive substrates are expensive and dimensionally inflexible, requiring complex tools and lacking a satisfactory method for permanent and secure connection without conventional joining methods.
Innovation Solution
A wire-connecting element with a two-zone portion, comprising a pre-mounting portion for wire winding attachment and a final mounting portion for forming a contact region, allowing direct plugging into a printed circuit board or substrate, where the wire winding is moved from the pre-mounting to the final mounting portion to establish a permanent connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If press-in contacts are used to connect wires to printed circuit boards, then connection reliability is improved, but manufacturing cost increases and dimensional flexibility is reduced
Solution Approach 1:
The contact element is divided into two functional zones: a pre-mounting portion for wire winding attachment and a final mounting portion for forming the contact region. This segmentation allows the wire to be wound around the pre-mounting portion and then transferred to the final mounting portion, eliminating the need for expensive specialized tools while maintaining secure connection reliability.
Solution Approach 2:
The wire is preliminarily wound around the pre-mounting portion before being transferred to the final mounting portion. This preliminary winding action secures the wire in position and allows for easy manipulation and transfer to the contact region without requiring complex joining methods or specialized equipment.
2Reliability
If conventional joining methods such as soldering or welding are used, then permanent connection is achieved, but manufacturing cost and process complexity increase
Solution Approach 1:
By separating the wire attachment function (pre-mounting portion) from the contact function (final mounting portion), the invention enables permanent connection through simple mechanical winding and transfer operations, eliminating the need for soldering or welding equipment and processes.
Solution Approach 2:
The wire-connecting element itself provides the means for permanent connection through its two-zone structure. The wire winds around the pre-mounting portion and is then transferred to the final mounting portion, where the element's geometry automatically secures the wire without requiring additional filler materials or complex joining methods.
3Strength
If press-in contacts with force-fit and form-fit components are used, then holding force is increased, but deformations occur in the contact and receptacle
Solution Approach 1:
The two-zone structure separates the wire securing function from the contact function. The wire winding around the pre-mounting portion creates the holding force without requiring deformations, and the transfer to the final mounting portion maintains this secure connection while preserving the structural integrity of both the contact element and the receptacle.
4Volume of moving object
If wire windings are made small to fit in compact spaces, then space utilization is improved, but wire winding and transfer becomes more difficult
Solution Approach 1:
The pre-mounting portion provides a three-dimensional structure around which the wire can wind in multiple turns, effectively utilizing vertical and radial space rather than only linear space. This allows compact wire windings that are easy to manipulate and transfer to the final mounting portion.
Data Source
AI summary
A wire-connecting element for connecting a metal wire to a circuit board or to an electrically conductive substrate via a connecting portion (V) of the wire-connecting element. The wire-connecting element has a two-zone portion (Z), which consists of a pre-mounting portion (B) and an adjoining final mounting portion (C). The pre-mounting portion (B) is designed for the attachment of a wire winding (IO). The final mounting portion (C) forms a contact region for the wire winding (IO), which wire winding, in the intended use, is moved, preferably pressed, onto the final mounting portion (C) after the wire winding (IO) has been attached around the pre-mounting portion (B).