Electrical Connector Terminal Blocking Portion for Flux Intrusion
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Solution Overview
Problem
Existing electrical connectors face issues during the welding process as soldering flux can easily enter the slots of the terminals, causing unwanted flux intrusion into the connector.
Innovation Solution
The electrical connector design features terminals with an interference portion having two barbs and a blocking portion connecting the interference and soldering leg, where the blocking portion's width is greater than the interference portion, preventing soldering flux from entering the slot.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal includes a narrow interference portion retained in the slot, then the terminal can be securely retained in the slot, but soldering flux can easily climb into the slot from the soldering leg
Solution Approach 1:
The blocking portion extends in the width direction (lateral dimension) beyond the interference portion, creating a dimensional barrier that prevents soldering flux from climbing into the slot. This lateral extension blocks the upward path of flux without interfering with the vertical retention function of the interference portion in the slot.
Solution Approach 2:
The terminal is segmented into distinct functional portions: the interference portion for retention, the blocking portion for flux prevention, and the soldering leg for welding. This segmentation allows each portion to perform its specific function independently, with the blocking portion specifically addressing the flux intrusion problem.
2Object-affected harmful factors
If the blocking portion width is greater than the interference portion width, then soldering flux is blocked from entering the slot, but the terminal structure becomes more complex
Solution Approach 1:
The blocking portion is merged with the interference portion as a single continuous structure of the terminal, rather than being a separate component. This integration reduces the number of parts and simplifies manufacturing while still providing the flux-blocking function through the width variation.
Solution Approach 2:
The terminal structure serves multiple functions: the interference portion provides mechanical retention in the slot, the blocking portion prevents flux intrusion, and the soldering leg enables welding to the circuit board. This multi-functionality is achieved within a single integrated terminal component.
Data Source
AI summary
An electrical connector includes an insulative housing and a number of terminals retained in the insulative housing. The insulative housing has a mating surface, a mounting surface, and a slot going through the mounting surface. The terminal received in the slot includes an interference portion retained in the slot, a contacting portion disposed around the mating surface, and a soldering leg extending downwardly beyond the mounting surface. The interference portion has two barbs disposed at two opposite sides thereof, respectively. The terminal includes a blocking portion connecting between the interference portion and the soldering leg. The width of the blocking portion is greater than the width of the interference portion.