Welded PCB Connecting Post for Stress-Free Board Assembly
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Solution Overview
Problem
Existing screw connections between circuit boards in electrical devices and electric drive systems lead to thread wear and stress concentration, hindering stable connections and space utilization for electronic components.
Innovation Solution
A conductive connecting post with welded ends inserted into mounting holes on opposite circuit boards, avoiding stress concentration and enabling stable, space-efficient integration of electronic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If screw connections are used to connect circuit boards, then assembly is simple and adjustable, but thread wear occurs and stress concentration damages the circuit board
Solution Approach 1:
The patent replaces the mechanical screw connection system with a welding system. The conductive connecting post is welded directly to the circuit board at the mounting hole location, eliminating threaded holes and screw-fastening mechanisms. This substitution eliminates thread wear issues and stress concentration around threaded holes while maintaining strong mechanical and electrical connection.
Solution Approach 2:
The invention extracts and removes the threaded hole structure from the circuit board design. By using welding instead of screw connections, the threaded holes are completely eliminated, removing the source of stress concentration and thread wear problems while simplifying the overall connection structure.
2Strength
If threaded holes are created in circuit boards for screw connections, then mechanical fastening is achieved, but stress concentration prevents electronic component placement
Solution Approach 1:
The welding-based connection system replaces the screw-fastening system that requires threaded holes. This substitution provides sufficient mechanical strength through weld bonds while eliminating the need for threaded holes, thereby preserving the entire circuit board surface for electronic component placement.
Solution Approach 2:
The connection strength is localized precisely at the mounting hole where the conductive connecting post meets the circuit board through welding. This localized bonding provides mechanical fastening strength exactly where needed without creating stress concentration zones that would restrict component placement in surrounding areas.
3Ease of manufacture
If conventional connection methods are used, then assembly is straightforward, but space utilization is reduced due to stress concentration zones
Solution Approach 1:
Replacing screw connections with welding eliminates the need for threaded holes and associated clearance zones, maximizing the usable space on circuit boards and enabling more compact device designs while maintaining straightforward assembly processes through standardized welding procedures.
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
Facilitates enduring stable connections and maximizes space utilization by eliminating stress concentration, allowing for miniaturized construction and efficient assembly.
Implementation Method 1
The first connecting end of the conductive connecting post is inserted into the first mounting hole and welded to the first circuit board at the first mounting hole; and the second connecting end of the conductive connecting post is inserted into the second mounting hole and welded to the second circuit board at the second mounting hole
Data Source
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AI summary
The present disclosure proposes an electrical device (10), comprising: a first circuit board (100), which is provided with a first mounting hole (150), and comprises a first outer surface and a first inner surface that are opposite each other; a second circuit board, which is provided with a second mounting hole, and comprises a second outer surface and a second inner surface that are opposite each other; and a conductive connecting post, comprising a first connecting end and a second connecting end, wherein the first circuit board and the second circuit board are arranged such that the first inner surface and the second inner surface are opposite each other; the first connecting end of the conductive connecting post is inserted into the first mounting hole and is welded to the first circuit board at the first mounting hole; and the second connecting end of the conductive connecting post is inserted into the second mounting hole and is welded to the second circuit board at the second mounting hole. The present disclosure also relates to an electric drive system, which comprises such an electrical device. The present disclosure also relates to a vehicle, which comprises such an electrical device or such an electric drive system.