Flat Solder Electrical Connector for Reduced Terminal Pitch
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Solution Overview
Problem
Existing electrical connectors face challenges in achieving a small terminal pitch due to the space occupied by spherical solder, leading to increased production costs and the risk of short circuits from excessive solder paste.
Innovation Solution
The electrical connector features flat-shaped solder with abutting surfaces and conductive terminals formed by stamping and bending, allowing for reduced terminal pitch and reduced solder paste usage, with clamping legs to securely position the solder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If spherical solder is used in the electrical connector, then the soldering function is achieved, but the terminal pitch cannot be reduced due to the large space occupied by the spherical solder
Solution Approach 1:
The solder is changed from a spherical shape to a flat plate shape, fundamentally altering its geometric parameters. This shape transformation reduces the volume occupied by the solder in the plate thickness direction, enabling smaller terminal pitch while maintaining effective soldering area
Solution Approach 2:
The solder geometry is transformed from a three-dimensional sphere to a flattened plate structure, effectively utilizing the plate thickness direction to reduce horizontal footprint. This dimensional change allows the solder to fit within the terminal width constraints while maintaining adequate soldering capability
2Area of stationary object
If a large amount of solder paste is coated on the pad to cover the spherical solder, then complete coverage is achieved, but production cost increases and short circuit risk increases
Solution Approach 1:
The flat plate shape of the solder reduces the required solder paste coverage area compared to spherical solder. The optimized geometry allows solder paste to effectively cover the essential areas without excessive application, reducing both material consumption and short circuit risk from paste overflow
Data Source
AI summary
An electrical connector includes: an insulating body, having a plurality of receiving slots formed through the insulating body; a plurality of conductive terminals, each disposed in one of the receiving slots, wherein the conductive terminal is formed with a solder contact surface, and the solder contact surface is substantially vertical; and a plurality of solders, respectively received in the receiving slots, in which the solder is in a flat shape, and each of the solders is formed with an abutting surface in a flat direction for abutting the solder contact surface.