Electric Part Soldered to PCB with Stepped Solder Space
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Solution Overview
Problem
Conventional electric connectors face challenges in achieving high peel resistance when soldered to metal pads on printed circuit boards, leading to unreliable electrical connections under oscillation, impact, and cable pull forces, due to limited soldered area and potential notch breakage during manufacturing.
Innovation Solution
The design incorporates a solder-filled space between the first and third surfaces of the electric part, with the second surface inclined relative to the first, creating a stepped portion that increases the soldered area and enhances peel resistance, while a method involving punching and reducing the thickness of metal parts forms the necessary contours without generating interfering burrs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the notch is cut by means of a cutter to form fillets, then the plated surface area is increased, but the notch may be broken before it is stretched to be thin
Solution Approach 1:
The notch is formed with preliminary dimensions and shape before the cutting process, ensuring it has sufficient structural integrity during manufacturing. The notch dimensions are designed such that it can be stretched to thin form without breaking, while still providing adequate plated surface area for solder attachment and peel resistance.
2Strength
If the soldered area is increased to enhance peel resistance, then the connection strength is improved, but the device complexity increases
Solution Approach 1:
The invention utilizes the vertical dimension by forming a notch that extends through the thickness of the electric part, creating upwardly bending fillets that increase soldered area in the vertical direction rather than expanding the horizontal footprint. This dimensional approach increases peel resistance without significantly increasing overall device complexity.
3Manufacturing precision
If the notch is stretched to be thin to ensure plated surface, then the solder wettability is improved, but the notch may break during cutting
Solution Approach 1:
The invention optimizes the parameters of the notch, including its initial width, depth, and position, to achieve the right balance between being stretchable to thin form for good plated surface quality and maintaining sufficient strength during the cutting process. The notch dimensions are carefully controlled to prevent breakage while ensuring adequate plated area.
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 configuration significantly increases the soldered area, resulting in enhanced peel resistance and reliability of the electrical connection, with the solder fillet providing strength against oscillation, impact, and cable pull forces, and ensuring consistent peel resistance.
Implementation Method 1
an electric part to be soldered to a metal pad formed at a surface of a printed circuit board
Implementation Method 2
solder is adhered to the second and third surfaces when the space is filled with solder
Implementation Method 3
a second surface extending from the first surface in a direction away from the printed circuit board, the second surface and the third surface defining a space in which solder is stored
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The electric part (30, 30x, 40, 40x) to be soldered to a metal pad (P1, P2) formed at a surface of a printed circuit board (P), includes a first surface (51, 61) facing the metal pad (P1, P2), a second surface (52, 62) extending from the first surface (51, 61) in a direction away from the metal pad (P1, P2), and a third surface (53, 63) outwardly extending from the second surface (52, 62), wherein the second surface (52, 62) and the third surface (53, 63) define a space (S1, S2) in which solder (B) is stored.