High-Current Contact Segmented Recesses for Solder Inspection
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Solution Overview
Problem
Existing high-current contacts face issues with air bubbles in soldered connections, low mechanical stability, and high solder consumption due to large gaps between conductors and contact elements, as well as incomplete connections in welded configurations, which are not easily inspectable.
Innovation Solution
The contact element features multiple recesses for distributing individual electrical conductors, allowing for reliable soldered or welded connections that can be visually inspected, reducing the risk of air bubbles and incomplete connections, and minimizing solder usage by filling smaller gaps, thus enhancing mechanical stability and compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single cup-shaped section is used to connect all electrical conductors, then the structure is simple, but air bubbles cannot be detected and mechanical stability is low
Solution Approach 1:
The single cup-shaped section is divided into multiple recesses (first recess, second recess, etc.), each accommodating individual electrical conductors. This segmentation allows for visual inspection of soldered connections and improves mechanical stability by distributing conductors across multiple smaller connection points rather than one large connection point.
2Quantity of substance
If solder fills large gaps between conductors and cup-shaped section, then connections are made, but solder consumption is very high and mechanical stability is low
Solution Approach 1:
By dividing the connection space into multiple small recesses, the total volume of solder required is significantly reduced compared to filling one large cup-shaped section. Each recess requires only a small amount of solder to fill the gap between the conductor and the recess surface, thereby reducing overall solder consumption while improving mechanical stability through distributed connections.
3Power
If high current intensities are used for operation, then power transmission is achieved, but trapped air bubbles cause connection impairment only after prolonged operation
Solution Approach 1:
The segmented recess design enables visual inspection of each soldered connection point, allowing trapped air bubbles to be detected before they cause connection impairment. This proactive detection prevents reliability issues from developing during high-current operation, as problematic connections can be identified and corrected before prolonged operation causes damage.
Solution Approach 2:
The design enables visual inspection of soldered connections, where the appearance and color of the solder joints can be examined to detect air bubbles or incomplete connections. This visual feedback mechanism allows for quality control that ensures reliable connections before high-current operation begins.
4Ease of manufacture
If conductors are bundled together, then connection process is simplified, but air bubbles are trapped and connections cannot be inspected
Solution Approach 1:
Instead of bundling all conductors together in a single connection point, each conductor is placed in its own recess. This segmentation maintains manufacturing simplicity by providing a clear, organized process for connecting each conductor individually, while simultaneously enabling easy visual inspection of each connection point to detect air bubbles or defects.
5Productivity
If a single large soldering area is used, then all conductors are connected at once, but mechanical stability is low and solder consumption is high
Solution Approach 1:
The connection process is divided into multiple smaller soldering operations at separate recesses rather than one large soldering area. This segmentation maintains productivity by allowing parallel processing of multiple conductors, while improving mechanical stability through distributed connection points that better distribute mechanical stresses.
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 design ensures reliable, inspectable connections with reduced solder consumption and improved mechanical stability, allowing for a compact and efficient high-current contact system.
Implementation Method 1
The cup-shaped section is filled with solder, thus creating the soldered connection between the electrical conductors and the contact element
Implementation Method 2
the solder only has to fill individual soldering gaps between the conductors and the recesses
Data Source
Figure 1~3
Figure 4~5
AI summary
The invention relates to a high-current contact (3) wherein several individual, electric conductors (6) of a common electric line (7) are soldered to the contact element (5) individually or in groups. According to the invention, the contact element (5) comprises a plurality of recesses (13) into which the electric conductors (6) are introduced. The soldered connection of the high-current contact (3) can be tested in a simple manner.