Formable Stopper Interference Fit for Solder-Blocked Assembly
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Solution Overview
Problem
Conventional coupling devices lack a reliable stopping mechanism to prevent solder from flowing into the assembly area, leading to assembly complications due to the solder layer interfering with the insertion process, and existing solutions like block members often fall off during installation due to vibration.
Innovation Solution
A formable stopper is designed to be extruded or fitted into a body's assembly portion, forming an interference structure that prevents the stopper from falling out and effectively blocks solder from entering the assembly area, using materials like Teflon, nylon, or silicone that remain secure during soldering processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a block member is arranged at the bottom of the hollow portion to prevent solder from entering, then solder flow prevention is improved, but the block member falls off due to vibration before the body is installed to the plate
Solution Approach 1:
The stopper is designed with elastic deformation capability, allowing it to dynamically adapt to the assembly hole geometry. The stopper deforms elastically during insertion and maintains continuous contact pressure against the hole walls, creating a dynamic retention mechanism that resists vibration-induced displacement while preventing solder ingress.
Solution Approach 2:
The stopper utilizes material parameter changes through elastic deformation. By selecting materials with appropriate elastic moduli and yield strengths, the stopper can deform under insertion force and then recover to maintain constant contact pressure against the assembly hole walls, ensuring reliable retention during vibration and effective solder blocking.
2Ease of operation
If the insertion portion is pressed against the solder layer during insertion, then assembly is achieved, but the solder layer enters the hollow portion due to lack of blocking
Solution Approach 1:
The stopper is pre-installed into the assembly hole before the soldering operation. This preliminary placement ensures that the blocking function is already in position to prevent solder intrusion, while the elastic properties allow the stopper to conform to the hole geometry and maintain secure retention during subsequent assembly and soldering operations.
Solution Approach 2:
The elastic stopper serves as an intermediary element between the assembly hole and the solder layer. It physically occupies the space that would otherwise be accessible to solder, creating a mechanical barrier that prevents harmful solder intrusion while allowing the insertion portion to pass through and complete the assembly operation.
Data Source
AI summary
A formable stopper applied to a fixing structure comprises a body having an assembly hole or an assembly section. The assembly hole or the assembly section includes a placement portion and an assembly portion. The assembly portion is in communication with or connected to the placement portion, or the placement portion is the assembly portion. The formable stopper further comprises a formable body. The formable body is adapted to be extruded, placed, or fitted into the placement portion, and extruded, placed, or fitted into the assembly portion, so as to form an interference structure or to form an interference force for preventing or avoiding the formable body from falling out of the assembly hole.