Organizer Cavities for Electrical Assembly Short Circuit Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In electrical assemblies, such as connectors and printed circuit boards, the solder reflow process often results in undesirable short circuits due to solder flow between adjacent contact pads, compromising the isolation and electrical communication of conductor ends.
Innovation Solution
An organizer with cavities and retention members is used to isolate and securely attach conductor ends to a complementary electrical component, preventing short circuits by physically and electrically isolating each cavity from others, and facilitating electrical communication through conductive material filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solder reflow process is used to mount cable conductor ends to contact pads, then electrical communication is established, but solder can flow onto adjacent contact pads creating short circuits
Solution Approach 1:
The patent divides the mounting structure into separate isolated cavities, each containing a conductor end and its corresponding contact pad. The organizer body creates physical segmentation that prevents solder from flowing between adjacent contact pads while maintaining electrical communication within each isolated cavity.
Solution Approach 2:
The organizer body acts as an intermediary structure between the cables and the substrate. It provides isolated cavities that mediate the soldering process by containing the solder within each cavity, preventing harmful solder flow to adjacent contact pads while still allowing electrical connection.
2Area of stationary object
If conductor ends are placed in close proximity for mounting, then space is utilized efficiently, but isolation between conductor ends is compromised
Solution Approach 1:
The organizer body is segmented into multiple isolated cavities that are arranged in close proximity. Each cavity provides isolation for its contained conductor end while the overall structure maintains compact area utilization by placing these segmented cavities adjacent to each other on the substrate.
Solution Approach 2:
Each cavity within the organizer body has the local quality of being electrically isolated from other cavities. This local isolation property is achieved through the organizer body structure that creates individual enclosed spaces, allowing close proximity mounting while maintaining reliability through localized electrical separation.
3Reliability
If organizer with multiple cavities is used to isolate conductor ends, then short circuits are prevented, but device complexity increases
Solution Approach 1:
The patent merges the functions of multiple isolated mounting structures into a single organizer body. Instead of using separate isolating structures for each conductor end, the organizer body combines multiple cavities into one integrated component that provides all necessary isolation functions, thereby reducing overall device complexity while maintaining short circuit prevention.
Solution Approach 2:
The organizer body serves multiple functions simultaneously: it provides mechanical support for multiple conductor ends, creates electrical isolation between them, defines mounting positions on the substrate, and prevents solder flow. This multi-functionality reduces the need for additional separate components, thereby managing device complexity while achieving reliable short circuit prevention.
Data Source
AI summary
Electrical assemblies including various complementary electrical components and plurality of cables are provided. Components of the electrical assemblies are configured such that respective signal conductor ends of the plurality of electrical cables can be isolated from one another and placed in electrical communication with the complementary electrical components using a conductive material. In accordance with some embodiments, the electrical assemblies include organizers that define respective pluralities of cavities and are configured to be attached to the complementary electrical components. In accordance with another embodiment, a leadframe assembly can define a plurality of cavities. The cavities of each of the pluralities of cavities are isolated from each other such that respective signal conductor ends of the plurality of electrical cables can be inserted into respective ones of the pluralities of cavities and placed into electrical communication with the respective complementary electrical components by filling the cavities with conductive material.