Electrical Element Trough Structure for Stable Component Soldering
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Solution Overview
Problem
In the production of electrical elements like ribbon cables for monitoring battery cells, temperature-sensitive components often shift during processing, leading to defective soldering due to changes in position and orientation.
Innovation Solution
A trough is formed in the recess of the electrical element by plastic deformation, extending from one conducting element to another, to maintain alignment and secure the component, allowing for automatic positioning and improved holding without interfering with the carrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the electrical component is inserted into the recess without additional positioning structures, then the insertion process is simple and quick, but the component shifts during processing resulting in defective soldering
Solution Approach 1:
The trough is formed in the recess before the electrical component is inserted, creating a pre-positioning structure that guides and secures the component in the correct location during subsequent soldering operations. This preliminary structural preparation prevents component shifting without complicating the insertion process.
Solution Approach 2:
The trough acts as an intermediary structure between the recess and the electrical component, providing a positioning interface that ensures accurate component placement. The trough mediates the interaction between the component and the electrical element, preventing direct contact issues and maintaining precise positioning during processing.
2Stability of the object's composition
If a trough is formed in the recess to secure the component, then the component positioning stability is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The recess is segmented into two functional zones: the trough portion that provides positioning and securing, and the remaining recess space that allows access and soldering operations. This segmentation enables the trough to perform its stabilizing function without interfering with the soldering process or requiring additional complex structures.
Solution Approach 2:
The trough is formed only in the specific area where positioning is needed, rather than modifying the entire recess structure. This localized modification provides the necessary component stability while minimizing structural complexity and leaving the rest of the recess simple and accessible for soldering operations.
3Manufacturing precision
If the trough extends from one conducting element to another, then the component alignment is improved, but the conducting elements become less exposed
Solution Approach 1:
The trough extends partially between the conducting elements, providing sufficient alignment and positioning functionality without completely covering the conducting elements. This partial extension achieves the necessary alignment precision while maintaining adequate exposure of the conducting elements for soldering operations.
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 prevents the electrical component from shifting during soldering, reducing defective products by ensuring correct positioning and secure attachment, thus enhancing the reliability of the electrical element.
Implementation Method 1
A trough is formed in the recess of the electrical element by plastic deformation, extending from one conducting element to another
Data Source
AI summary
An electrical element includes a pair of conducting elements spaced from one another, a recess receiving an electrical component, and a trough extending from a first conducting element of the pair of conducting elements to a second conducting element of the pair of conducting elements. The conducting elements are at least partially exposed in the recess.