PCB Cable Assembly Cold Welding for Low-Impedance Connection

Solution Overview

Problem

Existing soldering methods for cable assemblies introduce thermal stress and impedance issues, leading to potential damage and poor electrical performance due to high-temperature soldering processes.

Innovation Solution

A cable assembly that connects the inner conductor to a metal connection portion on a printed circuit board through a cold welding process, eliminating the need for solder and enhancing mechanical and electrical connectivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If hot bar soldering or laser soldering is used to connect cable to PCB, then soldering efficiency and product yield are improved, but thermal stress causes PCB expansion/contraction and internal circuit cracking

Engineering Contradiction:

Improvesoldering efficiencyVSAvoidthermal stress

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the thermal field (soldering) with a mechanical field (cold welding). Instead of using high-temperature soldering processes, the invention applies pressure and cold welding current to directly bond the cable conductor to the PCB pad, eliminating thermal stress while maintaining connection strength

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the fundamental parameter of the joining process from high temperature to room temperature. By using cold welding with controlled pressure and current, the process transitions from thermal bonding to mechanical/electrical bonding, resolving the thermal stress issue

Inventive Principle:

Principle #35Parameter changes

2Loss of time

If high-temperature soldering process is used, then soldering speed is improved, but rapid heating and cooling cause PCB expansion and contraction leading to internal circuit cracks

Engineering Contradiction:

Improvesoldering timeVSAvoidPCB structural integrity

Core Design Contradiction:

Loss of timeVSStability of the object's composition

Solution Approach 1:

The patent replaces the thermal field (soldering) with a mechanical field (cold welding). Instead of using high-temperature soldering processes, the invention applies pressure and cold welding current to directly bond the cable conductor to the PCB pad, eliminating thermal stress while maintaining connection strength

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If solder is used for connection, then mechanical bonding is achieved, but characteristic impedance at solder point increases affecting impedance matching

Engineering Contradiction:

Improvemechanical bondingVSAvoidimpedance matching

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent replaces the thermal field (soldering) with a mechanical field (cold welding). Instead of using high-temperature soldering processes, the invention applies pressure and cold welding current to directly bond the cable conductor to the PCB pad, eliminating thermal stress while maintaining connection strength

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent achieves homogeneous material contact by directly bonding similar metals (copper to copper or copper to copper alloy) through cold welding, eliminating the heterogeneous solder joint interface. This homogeneity ensures consistent electrical properties and characteristic impedance along the connection path

Inventive Principle:

Principle #33Homogeneity

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

The cold welding process improves electrical performance by reducing impedance and ensuring better impedance matching between the connector and cable, thereby minimizing thermal stress and enhancing the overall electrical characteristics.

Implementation Method 1

the conductor contact portion is mechanically and electrically connected to the metal connection portion by a cold welding process

Methodology Applied

Scientific EffectCold welding: Welding

Data Source

PatentUS20250392064A1Cable assembly

Publication Date: 2025.12.25 FOXCONN (KUNSHAN) COMPUTER CONNECTOR CO LTD

AI summary

A cable assembly includes: a cable having an inner conductor, the inner conductor having a conductor contact portion; and a printed circuit board connected to the cable; wherein the printed circuit board includes a metal connection portion, and the conductor contact portion is mechanically and electrically connected to the metal connection portion by a cold welding process.