Barrel Terminal Soldering with Segmented Non-Solder Surfaces
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Solution Overview
Problem
Conventional high-current electrical connectors experience poor soldering effects due to solder material creeping onto the contact area during heating, leading to inadequate fixation between the sleeve and barrel type terminal, which affects current transmission.
Innovation Solution
The electrical connector design includes a barrel type terminal with specific soldering and non-soldering surfaces, and a sleeve with corresponding fixing areas, where additional solder layers are applied between these areas to enhance soldering, using high-frequency soldering to prevent solder material from creeping onto the contact area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional reflow oven heating is used to solder the sleeve and barrel type terminal, then the soldering process is simple and quick, but the solder material creeps to the contact area reducing solder amount and poor soldering effect
Solution Approach 1:
The connecting area is divided into distinct regions: a first connecting area for soldering to the sleeve and a second connecting area for wire bonding, with a non-soldering surface separating them. This segmentation prevents solder material from creeping onto the contact area while ensuring adequate solder is present at the soldering interface, thus resolving the contradiction between fast soldering and precise solder amount control.
Solution Approach 2:
Different surfaces of the barrel type terminal are given different properties: the first connecting area is made solder-receptive while the contact area is made non-solder-receptive. This local differentiation ensures that solder material only adheres where needed (at the sleeve interface) and does not creep onto the contact area, maintaining both soldering effectiveness and contact area integrity during the quick reflow process.
2Strength
If solder material is increased to ensure adequate fixation, then the fixation between sleeve and barrel type terminal is improved, but solder material may creep to the contact area during heating
Solution Approach 1:
The terminal structure is segmented into a soldering region (first connecting area) and a non-soldering region (contact area and second connecting area). This allows sufficient solder material to be applied to the first connecting area for strong fixation with the sleeve, while the non-soldering surfaces prevent solder creep onto the contact area, eliminating the harmful effect of solder contamination.
Solution Approach 2:
The surface properties are locally differentiated such that the first connecting area has high solder wettability for strong joint formation, while the contact area has low solder wettability to prevent creep. This local quality control enables strong fixation without the harmful side effect of solder material migrating to the contact area during heating.
3Reliability
If the contact area is protected from solder material, then the current transmission effect is improved, but the soldering process becomes more complex
Solution Approach 1:
The terminal is designed with distinct segmented areas: a first connecting area for soldering and a second connecting area for wire bonding, separated by a non-soldering surface. This segmentation inherently protects the contact area from solder material during the soldering process, ensuring reliable current transmission without requiring additional protective measures or complex process steps.
Solution Approach 2:
The contact area is given a non-solder-receptive surface property while the first connecting area has a solder-receptive property. This local quality differentiation automatically prevents solder material from adhering to the contact area during the standard reflow soldering process, maintaining reliable electrical contact without increasing process complexity.
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
This design ensures a robust soldering effect, reducing contact resistance and improving heat dissipation by maintaining a larger conductive area with sufficient solder between the fixing and soldering surfaces, thus enhancing the fixation and reliability of the connector.
Implementation Method 1
the first fixing area and the first soldering surface are heated and soldered
Implementation Method 2
the second fixing area and the second soldering surface are heated and soldered
Implementation Method 3
using high-frequency soldering to prevent solder material from creeping onto the contact area
Data Source
AI summary
An electrical connector includes a barrel type terminal, having a first connecting area and a second connecting area. The first connecting area has a first non-soldering surface and a first soldering surface. The second connecting area has a second non-soldering surface and a second soldering surface. Each of the first and second soldering surfaces and the first and second non-soldering surfaces has a first solder layer. A sleeve sheathes outside the barrel type terminal, and has a first fixing area and a second fixing area. Two second solder layers are provided between the first fixing area and the first soldering surface and between the second fixing area and the second soldering surface. The amount of solder provided between the first fixing area and the first soldering surface and between the second fixing area and the second soldering surface is greater than that provided on the first and second non-soldering surfaces.