Wire Lug Connector With Compliant Pins For Direct Substrate Mounting
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Solution Overview
Problem
Existing power connector systems are costly and complex due to the need for multiple interfaces and require special operations or tooling for connection to substrates like circuit boards or bus bars, whether through soldering or bolting.
Innovation Solution
A wire lug connector with a conductive base and compliant pins that can be directly press-fit or soldered to a substrate, eliminating the need for separate headers and reducing interfaces, using a dielectric housing to position and secure the lug for mechanical and electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional power connectors are used with separate headers mounted to substrates, then reliable electrical connection is achieved, but system cost increases and device complexity increases
Solution Approach 1:
The patent combines the power connector and header into a single integrated wire lug connector assembly. The lug directly mounts to the substrate with compliant pins that serve as both mechanical anchors and electrical contacts, eliminating the need for separate header components and reducing the number of interfaces while maintaining reliable electrical connection.
2Reliability
If traditional power connectors with separate headers are used, then electrical connection is established, but manufacturing cost increases
Solution Approach 1:
By integrating the connector and header functions into one component, the patent reduces part count and assembly steps. The compliant pins are formed as integral parts of the lug, eliminating the need for separate header manufacturing and installation processes, thereby reducing overall manufacturing cost while ensuring reliable electrical connection.
Solution Approach 2:
The compliant pins are designed to automatically establish both mechanical and electrical connection when the lug is mounted to the substrate. The pins flex to accommodate substrate variations and provide self-aligning, self-securing connection without requiring additional fastening operations or specialized tooling, simplifying manufacturing.
3Strength
If wire lugs are soldered or bolted to substrates, then secure connection is achieved, but special operations or tooling are required adding cost
Solution Approach 1:
The compliant pins are designed to automatically establish both mechanical and electrical connection when the lug is mounted to the substrate. The pins flex to accommodate substrate variations and provide self-aligning, self-securing connection without requiring additional fastening operations or specialized tooling, simplifying manufacturing.
Data Source
AI summary
A wire lug connector includes a lug having a termination end configured to be terminated to a conductor of a wire. The lug has a conductive base at a mounting end configured to be mounted to a substrate. The base has a plurality of compliant pins extending from a bottom of the base. The compliant pins are electrically connected to the conductor by the base. The compliant pins are configured to be mechanically and electrically connected to the substrate. The compliant pins may have double ended press-fit sections at opposite heads and tails of the compliant pins that are press-fit into corresponding openings in the base and vias in the substrate.