Stamped-Rolled Contact Sleeve for Compact PCB Solder Joints
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Solution Overview
Problem
Existing electrical contact elements for printed circuit boards face challenges in achieving sufficient mechanical stability and solder area while minimizing space requirements and production costs, especially in high-density contact systems.
Innovation Solution
An integral, stamped-rolled electrical contact element with a terminal portion and an adjoining soldered portion, featuring a sleeve slit with an interior space that can be continuously hollow, interrupted, or partially filled, enhancing stability and solder wetting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If thin sheet metal thickness (0.2-0.25 mm) is used to minimize space requirements, then space requirement is reduced, but mechanical stability and solder area are insufficient
Solution Approach 1:
The soldered portion is designed as a sleeve structure that can be inserted into the contact carrier, creating a nested configuration. This allows the thin-walled sleeve to gain structural support from the carrier while maintaining its compact external dimensions, thus achieving both small space requirement and sufficient mechanical stability.
Solution Approach 2:
The contact element combines thin-walled sleeve structure with solder material to create a composite assembly. The solder provides both mechanical strength and electrical connection, allowing the thin-walled portion to maintain compact size while the soldered joint provides the necessary stability and solder area.
2Volume of moving object
If thin sheet metal thickness (0.2-0.25 mm) is used to minimize space requirements, then space requirement is reduced, but solder area is insufficient
Solution Approach 1:
Instead of increasing solder area by increasing sheet metal thickness (one dimension), the invention uses the longitudinal dimension by creating a sleeve structure with length extension. The soldered portion extends in the longitudinal direction, providing adequate solder area while maintaining thin cross-sectional dimensions for compact space requirement.
3Area of stationary object
If J-terminal with 180° bent sheet metal is used to increase solder area, then solder area is increased, but production cost increases due to greater material dimensions
Solution Approach 1:
The invention changes the geometric parameters of the soldered portion, specifically creating a sleeve structure with optimized length and diameter ratios. This allows achieving adequate solder area with smaller overall material dimensions compared to the 180° bent J-terminal, thereby reducing material consumption and production cost.
4Area of stationary object
If turned contact with solid rear region is used to provide sufficient solder area and stability, then solder area and stability are sufficient, but weight increases
Solution Approach 1:
The invention uses a thin-walled sleeve structure instead of a solid rear region. The thin-walled sleeve provides adequate solder area for connection while minimizing material usage and weight. The sleeve geometry is optimized to provide sufficient structural support without requiring solid filling, thus achieving weight reduction.
5Ease of operation
If L-shaped wall terminal is used, then contact can be established, but de-concentration of contacts requires high space requirement
Solution Approach 1:
The invention uses a cylindrical/sleeve geometry for the soldered portion instead of the L-shaped configuration. The cylindrical form factor provides compact dimensional footprint in all directions, enabling better contact concentration and reduced space requirement while maintaining effective electrical contact establishment.
Data Source
AI summary
An integral stamped-rolled electrical contact element, comprising: a terminal portion and an adjoining soldered portion for electrically contacting a contact face by a soldered connection. The soldered portion has a sleeve slit in a longitudinal direction. An interior space of the soldered portion is at least one of continuously hollow, interrupted, or at least partially filled in the longitudinal direction.