Electrical Connector Assembly Method Using Selective Terminal Heating

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Solution Overview

Problem

Conventional electrical connector assembly methods require significant thermal energy for soldering, leading to energy waste and potential deformation of insulating bodies during the pre-soldering process.

Innovation Solution

An electrical connector assembly method where the soldering portion of the terminal is heated to a melting temperature and the solder is press-fitted using a jig, eliminating the need to heat the insulating body and reducing thermal energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If all components are placed in a heating apparatus for pre-soldering, then the solder and soldering portion are fixed, but much thermal energy is needed causing energy waste

Engineering Contradiction:

Improvefixing of solder and soldering portionVSAvoidthermal energy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The heating process is segmented into two stages: first, only the soldering portion is heated to melt the solder; second, the entire assembly (insulating body, conducting terminals, solder, and positioning tool) is heated together for pre-soldering. This segmentation allows selective heating to reduce energy waste while ensuring proper fixation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The solder is pre-positioned on the soldering portion using a positioning tool before the final pre-soldering process. This preliminary positioning ensures that the solder is correctly placed and will be properly fixed during the subsequent heating and pre-soldering stage, improving the reliability of the connection.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If all components are placed in a heating apparatus for pre-soldering, then the solder and soldering portion are fixed, but the insulating body is heated causing warping and deformation

Engineering Contradiction:

Improvefixing of solder and soldering portionVSAvoidshape stability of insulating body

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The heating process is divided into two distinct stages: first, selective heating of only the soldering portion to melt the solder without heating the insulating body; second, simultaneous heating of all components for pre-soldering. This segmentation prevents the insulating body from being exposed to excessive heat that would cause warping and deformation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The solder is pre-positioned on the soldering portion before the final heating stage. This preliminary action ensures that when the entire assembly is heated together, the solder is already in the correct position and will be properly fixed, while the insulating body is not subjected to prolonged individual heating that would cause deformation.

Inventive Principle:

Principle #10Preliminary action

3Use of energy by moving object

If the soldering portion is heated to melting temperature and solder is press-fit using a jig, then energy consumption is reduced, but the process requires precise temperature control

Engineering Contradiction:

Improvethermal energy consumptionVSAvoidtemperature control precision

Core Design Contradiction:

Use of energy by moving objectVSManufacturing precision

Solution Approach 1:

The heating process uses parameter changes by controlling the temperature to reach the melting point of the solder and then stopping heating at the appropriate moment. This parameter control allows the solder to melt and fuse with the soldering portion while minimizing energy consumption and preventing overheating of the insulating body.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The conventional mechanical press-fitting of solder is replaced with a thermal process where the soldering portion is heated to melt the solder, which then fuses naturally when pressed. This substitution reduces the need for high mechanical pressure and allows for more precise control of the joining process through temperature management.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 method saves energy, reduces production costs, and prevents insulating body deformation by only heating the soldering portion, while ensuring a secure electrical connection.

Implementation Method 1

the soldering portion is heated by high-frequency current induction

Methodology Applied

Scientific EffectHigh-frequency current induction: Electromagnetic Induction

Implementation Method 2

heating the soldering portion to a melting temperature of a solder; press-fitting the solder to the soldering portion... so that the solder is fused and fixed to the soldering portion

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS10547152B2Electrical connector assembly method

Publication Date: 2020.01.28 LOTES

AI summary

An electrical connector assembly method, including the steps of: step 1: providing a terminal having a soldering portion; step 2: heating the soldering portion to a melting temperature of a solder; step 3: providing the solder, and press-fitting the solder to the soldering portion by a jig, so that the solder is fused and fixed to the soldering portion; and step 4: inserting the terminal fixed with the solder into an insulating body. Because only the soldering portion of the terminal is heated, less thermal energy is needed, thereby saving energy and reducing the production cost of the electrical connector. Moreover, the insulating body does not need to be heated, thus preventing the insulating body from being warped and deformed due to heat.