Integrated Heated Jaw Soldering Tool for Dry Joint Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing soldering tools often result in defective joints due to relative movement of work pieces before the solder cools, leading to mechanically weak and electrically resistive 'dry joints'.
Innovation Solution
A soldering tool with a jaw and heating element, featuring a pivot mechanism and ergonomic handles, secures work pieces with longitudinal ridges and grooves, and uses ceramic or metal resistive heating elements to maintain the solder in a molten state while allowing for efficient crimping and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional soldering tools are used to heat work pieces, then the solder can be melted and applied to the joint, but the work pieces may move relative to each other before the solder cools, resulting in defective dry joints
Solution Approach 1:
The patent combines the heating function and the clamping function into a single integrated tool. The jaws of the plier incorporate heating elements that can simultaneously heat the work pieces and maintain clamping pressure, ensuring the work pieces remain stable and properly positioned throughout the soldering process without requiring separate tools or manual intervention.
Solution Approach 2:
The heated jaws act as an intermediary between the heat source and the work pieces, providing both thermal energy and mechanical constraint. The jaws transfer heat to the work pieces while simultaneously maintaining clamping force, preventing movement and ensuring proper joint formation during the critical cooling period.
2Manufacturing precision
If the work pieces are held together manually during soldering, then the solder can cool and solidify, but the process is time-consuming and prone to human error
Solution Approach 1:
The tool is designed to be self-sufficient by integrating the heating elements directly into the jaws. When the user closes the plier on the work pieces, the heating elements automatically activate and maintain temperature, and the mechanical structure automatically maintains clamping pressure throughout the soldering process, eliminating the need for continuous manual adjustment or monitoring.
Solution Approach 2:
The heating elements provide continuous heat throughout the entire soldering process, from melting the solder through to its solidification. The clamping force is also maintained continuously, ensuring uninterrupted thermal and mechanical action, which accelerates the process and ensures consistent results without requiring multiple steps or interventions.
3Strength
If a soldering iron is used to heat work pieces, then the solder can be melted, but the tool cannot simultaneously apply crimping force to secure the connection
Solution Approach 1:
The tool performs multiple functions simultaneously: it acts as a mechanical fastener through its clamping action, as a heating device through its integrated heating elements, and as a positioning device through its jaw structure. This multi-functionality allows the user to complete crimping, heating, and holding operations with a single tool, eliminating the need for separate soldering irons and crimping tools.
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
Enables faster, more repeatable, and efficient soldering with improved mechanical and electrical conductivity of joints, reducing production costs and minimizing defective joints.
Implementation Method 1
uses ceramic or metal resistive heating elements to maintain the solder in a molten state
Implementation Method 2
uses ceramic or metal resistive heating elements to maintain the solder in a molten state
Data Source
AI summary
The present disclosure comprises methods, apparatus, components, and techniques for soldering. A soldering tool includes opposing jaw pieces adapted to grip and/or compress work pieces while applying heat. The work pieces can be heated to a temperature at or above the melting point of a solder material, whereupon the solder may be melted and applied at the work pieces. The soldering tool may be removed from the work pieces, thereby allowing the solder to solidify and form a soldered joint. Soldering tools may be powered by portable, rechargeable, and/or detachable battery packs that are readily accessible and commonly used for a wide variety of hand-operated power tools.