Cable Connector Staggered Shielding for Laser Soldering
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Solution Overview
Problem
Conventional cable connector assemblies face issues with deformation and insulating layer damage of non-coaxial cables during laser soldering, leading to potential short-circuiting and electrical leakage due to high temperatures.
Innovation Solution
The cable connector assembly design includes a staggered arrangement of insulating layers and contact areas, allowing for laser soldering without damaging the non-signal cable's insulating layer, ensuring its integrity and enabling continuous soldering processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser soldering is used to increase soldering efficiency, then productivity is improved, but the insulating layer of non-coaxial cable is damaged due to high temperature
Solution Approach 1:
The patent divides the cable assembly into distinct segments: signal cables with their insulating layers and non-signal cables without insulating layers. This segmentation allows the laser soldering process to be applied to the non-signal cable area without affecting the signal cable's insulating layer, as they are spatially separated. The shielding layer is positioned to create a physical barrier that protects the insulating layer during laser soldering of adjacent areas.
Solution Approach 2:
The shielding layer acts as an intermediary element between the laser soldering process and the insulating layer. It serves as a thermal barrier that absorbs or reflects the laser energy, preventing it from reaching and damaging the insulating layer. This intermediary structure enables the use of high-temperature laser soldering while protecting temperature-sensitive components.
2Reliability
If conventional tin-soldering is used to avoid high temperature damage, then the insulating layer is protected, but soldering time is excessive
Solution Approach 1:
The patent segments the soldering process into two distinct operations: conventional tin-soldering for the signal cable connections where the insulating layer is present, and laser soldering for the non-signal cable connections where no insulating layer exists. This segmentation allows each process to be optimized for its specific requirements, maintaining reliability for signal connections while achieving high efficiency for non-signal connections.
Solution Approach 2:
The patent applies the more aggressive laser soldering method only partially - specifically to the non-signal cable areas where the insulating layer is absent. This partial application of excessive action (high-temperature laser soldering) achieves high productivity without causing damage, while the signal cable areas receive the gentler conventional soldering treatment.
3Reliability
If the shielding layer is soldered to the shielding sheet for good grounding effect, then electrical safety is improved, but the adjacent non-coaxial cable insulating layer is damaged by laser heat
Solution Approach 1:
The patent positions the shielding layer as an intermediary barrier between the laser soldering process and the insulating layer. This shielding layer acts as a thermal shield that protects the insulating layer from laser-induced heating while allowing the soldering process to proceed effectively on the non-signal cable connections.
Solution Approach 2:
The patent creates different local conditions in different areas of the cable assembly. The signal cable areas maintain their insulating layers and are protected from laser exposure, while the non-signal cable areas are designed without insulating layers and are the target of laser soldering. This local differentiation allows the grounding function to be achieved through laser soldering of the shielding layer without causing thermal damage to insulating structures.
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 prevents damage to the non-signal cable's insulating layer during laser soldering, maintaining its insulating effect and increasing soldering efficiency by ensuring the second insulating layer is not melted, thus avoiding short-circuiting and electrical leakage risks.
Implementation Method 1
laser soldering is usually adopted as the soldering method
Implementation Method 2
high temperature generated by laser soldering
Data Source
AI summary
A cable connector assembly, including: a body; a signal terminal and a non-signal terminal accommodated in the body, the signal terminal having a first wire-bonding end extending outside the body, and the non-signal terminal having a second wire-bonding end extending outside the body; a shielding sheet provided on the body, and having a soldering portion extending outside the body; a signal cable having a first core laser soldered to the first wire-bonding end, and a shielding layer wrapping on the first core and electrically connected with the soldering portion to form a contact area; and a non-signal cable having a second core and a second insulating layer wrapping on the second core. A front end of the contact area is flush with a rear end of the second insulating layer or is located behind it.