Battery Lead Connection to Circuit Board Nodes
Solution Overview
Problem
Conventional circuit board assembly processes face issues with intermittent connectivity between live battery leads and nodes, causing voltage fluctuations that can damage circuit components due to rapid make and break connections.
Innovation Solution
A method involving electrically isolated nodes on a circuit board with a gap between them, where a conductive lead is initially contacted to one node and then an electrical connection is formed via soldering, creating a low impedance path to the other node, thus preventing initial damage from live voltage application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If battery leads are aligned and loosely contacted to nodes on the circuit board before soldering, then the assembly process can proceed, but intermittent connectivity causes rapid voltage fluctuations that damage circuit components
Solution Approach 1:
The patent applies preliminary action by pre-soldering the battery lead to the first node before bringing it into contact with the second node. This ensures that the electrical connection is already established and stable before voltage is applied during the assembly process, preventing the intermittent connectivity and voltage fluctuations that would otherwise damage sensitive circuit components.
2Reliability
If battery leads are directly soldered to nodes on the circuit board, then a permanent connection is achieved, but the process is complex and time-consuming
Solution Approach 1:
The patent applies segmentation by dividing the connection process into two distinct stages: first, soldering the battery lead to the first node (creating a stable anchor connection), and second, bringing the lead into contact with the second node (completing the circuit connection). This segmentation simplifies each individual step while ensuring a reliable permanent connection, reducing overall process complexity compared to attempting to solder both nodes simultaneously.
3Productivity
If multiple battery leads are connected simultaneously to different nodes, then assembly speed is maintained, but voltage variations across different nodes cause component damage
Solution Approach 1:
The patent applies preliminary action by requiring that each battery lead be pre-soldered to its first node before being brought into contact with the corresponding second node. This ensures that each connection is stable and voltage-controlled before full circuit operation begins, preventing the harmful voltage variations that would occur with simultaneous multi-lead connection while still allowing systematic assembly of multiple leads.
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 controlled connection method reduces the likelihood of damage to circuitry by ensuring a stable, permanent connection after soldering, preventing voltage fluctuations during the assembly process.
Implementation Method 1
The solder and/or any portion of the combination can be heated to facilitate a flow of the solder. In such an embodiment, the heated solder flows across the first node, the second node, and the conductive lead to provide a highly, electrically conductive path
Implementation Method 2
The solder and/or any portion of the combination can be heated to facilitate a flow of the solder. In such an embodiment, the heated solder flows across the first node, the second node, and the conductive lead
Data Source
AI summary
An assembler receives a circuit board. The circuit board includes at least a first node and a second node that are adjacent but electrically isolated from each other. There is a gap between the first node and the second node. The first node is electrically isolated from other components on the circuit board. The second node is electrically coupled to circuitry residing on the circuit board. The assembler initiates positioning of a conductive lead of a battery in a vicinity of the first node. The gap between the first node and second node initially prevents the live conductive lead from being in electrical contact with the second node. Eventually, the assembler bridges the gap to provide an electrical connection between at least the conductive lead and the second node to electrically couple the conductive lead to the second node and thus the circuitry residing on the circuit board.