Electrical Connector Using Conductive Adhesive Bonding

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional electrical connectors rely heavily on manual soldering, leading to high personnel and material costs, and often suffer from poor soldering quality due to low controllability, resulting in issues like bridging and wicking.

Innovation Solution

An electrical connector design that uses a conductive adhesive layer to bond the conductive pins of a connecting cable directly to the electrical connector body, eliminating the need for soldering and thereby reducing costs and improving connection reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual soldering is used to assemble electrical connectors, then electrical connections can be formed, but personnel cost and material cost increase significantly

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the manual soldering process (mechanical/thermal system) with a conductive adhesive bonding system. The conductive adhesive layer is applied to the connector body, and conductive pins are pressed onto it, eliminating the need for soldering equipment, flux, and manual dexterity, thereby reducing both personnel and material costs while maintaining electrical connection reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the bonding mechanism from high-temperature soldering to low-temperature conductive adhesive bonding. This parameter change allows for automated assembly processes, reduces skill requirements for operators, and eliminates expensive soldering materials, directly addressing the cost issue while preserving electrical connectivity.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If manual soldering is used to assemble electrical connectors, then electrical connections can be formed, but soldering defects like bridging and wicking occur due to low controllability

Engineering Contradiction:

Improvesoldering qualityVSAvoidsoldering controllability

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent replaces the uncontrollable manual soldering process with a controlled conductive adhesive bonding process. The adhesive layer provides a consistent bonding interface, and the pressing operation ensures uniform contact between conductive pins and the connector body, eliminating soldering defects like bridging and wicking that result from poor manual controllability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If conductive adhesive layer is used to bond cables to connector body, then manufacturing cost decreases, but connection strength may be reduced compared to soldering

Engineering Contradiction:

Improvemanufacturing costVSAvoidconnection strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent uses conductive adhesive material that combines bonding adhesive properties with electrical conductivity. This composite material simultaneously provides mechanical bonding strength to hold conductive pins in place and electrical conductivity to transmit signals, achieving both cost reduction and adequate connection strength without requiring separate adhesive and conductive layers.

Inventive Principle:

Principle #40Composite materials

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 solution reduces labor and material costs while preventing soldering defects like bridging and wicking, ensuring reliable electrical connections without the need for high-temperature soldering processes.

Implementation Method 1

bonding the conductive pin of each cable of the connecting cable to the electrical connecting conductor of the electrical connector body through the conductive adhesive layer

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

The conductive pin of each of the cables forms an electrical connection path with the corresponding electrical connecting conductor

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS11316286B2Electrical connector

Publication Date: 2022.04.26 DONGGUAN LUXSHARE PRECISION IND CO LTD

AI summary

The present disclosure provides an electrical connector comprising an electrical connector body, a conductive adhesive layer, and a connecting cable. The electrical connector body comprises a plurality of electrical connecting conductors. The conductive adhesive layer covers the plurality of electrical connecting conductors. The connecting cable comprises a plurality of cables. One end of each of the cables comprises a conductive pin. The conductive pin of each of the cables is disposed on the conductive adhesive layer. The conductive pin of each of the cables forms an electrical connection path with the corresponding electrical connecting conductor. The plurality of electrical connection paths is individually separated. By combining the conductive pins of each cable with the electrical connecting conductors of the electrical connector body through a conductive adhesive layer, an electrical connection path could be formed to bond the connecting cable and the electrical connector body without any existing soldering process.