Elastic Rib Signal Connection for Solder-Free RF Substrate Assembly
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Solution Overview
Problem
Existing signal connection methods between substrate members require a soldering process, which increases product manufacturing cost, assembly time, and labor, and are prone to signal quality degradation due to external vibrations, especially in RF applications.
Innovation Solution
An assistant elastic part with an elastic rib that applies an elastic force to maintain electrical connection between substrate members, eliminating the need for soldering and ensuring RF characteristics by using a dielectric material with a dielectric constant of 2.7 to 3.5 and hardness of 60 HV to 75 HV.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a soldering process is used to connect substrate members, then electrical connection reliability is improved, but manufacturing cost and assembly time increase
Solution Approach 1:
The patent replaces the soldering process (thermal/mechanical system) with a mechanical pressing system. The elastic pressing part applies continuous elastic force to press the conductive patterns of substrate members together, establishing electrical connection through direct contact without melting or chemical bonding. This substitution eliminates the soldering process entirely, reducing assembly time and cost while maintaining connection reliability through sustained mechanical pressure.
Solution Approach 2:
The elastic pressing part serves as an intermediary component between substrate members. It transmits pressing force from the housing to the conductive patterns, ensuring stable electrical connection. The intermediary structure includes pressing portions that directly contact the conductive patterns and elastic portions that provide the restoring force, mediating the connection without requiring soldering materials or processes.
2Reliability
If a soldering process is used to connect substrate members, then electrical connection reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces the soldering process (requiring soldering materials, equipment, and complex processes) with a simple mechanical pressing system. The elastic pressing part can be integrated into the housing structure or assembled as a simple component, eliminating the need for soldering wires, solder paste, reflow ovens, and associated quality control processes, thereby significantly reducing manufacturing cost.
Solution Approach 2:
The elastic pressing part is designed as a simple, low-cost component that can be easily manufactured and replaced if needed. Rather than investing in expensive soldering materials and equipment, the patent uses inexpensive elastic materials (such as rubber or foam) and simple structural elements that achieve the same functional result at much lower cost.
3Device complexity
If substrate members are directly connected without elastic support, then assembly simplicity is improved, but connection stability under vibration decreases
Solution Approach 1:
The patent introduces dynamic characteristics to the connection system through the elastic pressing part. Instead of a rigid, static connection, the elastic portion allows for dynamic adjustment and compensation. The elastic material can deform and recover, adapting to variations in substrate positioning and maintaining stable contact pressure under external disturbances such as vibration, while still being relatively simple in structure.
Solution Approach 2:
The elastic pressing part provides beforehand cushioning against external vibrations and shocks. The elastic material absorbs and dissipates vibration energy before it can disrupt the electrical connection between substrate members. This pre-established cushioning mechanism protects the connection stability proactively rather than reacting to vibrations after they occur.
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
Reduces manufacturing costs by eliminating soldering, maintains RF characteristics, and improves signal quality with optimal isolation and return loss values, enabling automated assembly.
Implementation Method 1
an elastic rib that is provided to press the second substrate member by an elastic force of a material of the elastic rib
Data Source
Figure 1
Figure 2(a)~2(c)
Figure 3(a)~3(c)
AI summary
Provided are an assistant elastic part for signal connection and a substrate assembly including the same. The assistant elastic part for signal connection includes an elastic pressing part that, of a substrate assembly including a first substrate member and a second substrate member that is stacked so that one surface thereof is in surface-contact with the first substrate member, applies an elastic force to the second substrate member and maintains electrical signal connection between mutually facing surfaces of the first substrate member and the second substrate member, and the elastic pressing part includes an elastic rib that is provided to press the second substrate member by an elastic force of a material of the elastic rib, thereby reducing the product manufacturing cost and providing the advantage of maintaining RF characteristics with only low-cost components.