Solderable Elastic Contact Terminal Using Composite Core

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Solution Overview

Problem

Existing metal-based electric contact terminals face challenges in achieving excellent elasticity and electrical conductivity, particularly in a predetermined height, and require multiple press molds for different shapes, leading to increased costs and susceptibility to movement during surface mounting processes.

Innovation Solution

A solderable elastic electric contact terminal is designed with a tube-shaped insulating elastic core, an insulating non-foam rubber coating layer, and a heat-resistant polymer film with a metal layer, which provides improved elasticity and conductivity while reducing manufacturing costs and preventing movement during reflow soldering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a metal sheet is bent to increase elasticity, then elastic resilience is improved, but the height increases beyond predetermined height

Engineering Contradiction:

Improveelastic resilienceVSAvoidheight

Core Design Contradiction:

StrengthVSLength of moving object

Solution Approach 1:

The invention uses a composite structure consisting of an insulating elastic core made of elastomer material combined with a conductive metal layer. This composite material approach allows the contact terminal to achieve both elasticity from the elastomer core and electrical conductivity from the metal layer, while maintaining a compact height that meets predetermined requirements without needing to bend the structure excessively.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The insulating elastic core is designed as a tube-shaped flexible structure made of elastomer material. This flexible shell provides the necessary elasticity and mechanical resilience while maintaining a controlled height. The thin-walled tube structure allows sufficient elastic deformation without increasing the overall height beyond predetermined limits.

Inventive Principle:

Principle #30Flexible shells and thin films

2Adaptability or versatility

If additional press molds are used to form different shapes, then product shape variety is improved, but manufacturing cost increases

Engineering Contradiction:

Improveproduct shape varietyVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The invention separates the forming processes into two distinct stages: first, the insulating elastic core is formed using a single press mold; second, the metal layer is applied to the formed core. This segmentation allows the same basic core mold to be used for all products, while shape variations are achieved through the metal layer application process, eliminating the need for multiple expensive molds for different shapes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulating elastic core is pre-formed using a single press mold before the metal layer is applied. This preliminary formation of the core structure allows subsequent metal layer processing to create different final product shapes without requiring different core molds, thereby reducing manufacturing costs while maintaining shape variety.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If a metal sheet structure is used, then electrical conductivity is improved, but susceptibility to wind movement during surface mounting increases

Engineering Contradiction:

Improveelectrical conductivityVSAvoidwind movement susceptibility

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The composite structure combines a heavy elastomer core with a conductive metal layer. The elastomer core provides sufficient weight to resist wind movement during surface mounting processes, while the metal layer ensures high electrical conductivity. This material combination simultaneously addresses both conductivity requirements and resistance to external disturbances.

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

The solution enhances the elastic and electrical properties of the contact terminal, maintaining adhesive force and flexibility during soldering, reducing manufacturing costs, and preventing movement during surface mounting and reflow soldering processes.

Implementation Method 1

an insulating elastic core (10) having a tube shape

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

another surface integrally provided with a metal layer (40)

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 3

a insulating non-foam rubber coating layer (20) adhered to the insulating elastic core (10) to surround the insulating elastic core (10); and a heat-resistant polymer film (30) having one surface adhered to the insulating non-foam rubber coating layer (20)

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentEP2099269B1Solderable elastic electric contact terminal

Publication Date: 2012.04.25 JOINSET

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AI summary

Provided is a solderable elastic electric contact terminal. The solderable elastic electric contact terminal includes a tube-shaped insulating elastic core, an insulating non-foam rubber coating layer adhered to the insulating elastic core to surround the insulating elastic core, and a heat-resistant polymer film having one surface adhered to the insulating non-foam rubber coating layer to surround the insulating non-foam rubber coating layer, and another surface integrally provided with a metal layer.