PCB Cable Soldering Aid With Guided Strand Positioning
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Solution Overview
Problem
The existing methods for forming a solder connection between a cable strand and a circuit board are complex and require extensive preparation, making the process inefficient and time-consuming.
Innovation Solution
A soldering auxiliary part with an electrically insulating body featuring three recesses and an electrically conductive contact structure, allowing for the secure positioning and soldering of a cable strand to a circuit board connection, utilizing a reflow process for efficient connection formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional soldering methods are used to connect cable strands to circuit boards, then the connection can be formed, but the process becomes complex and time-consuming requiring extensive preparation
Solution Approach 1:
The soldering aid is divided into three distinct recesses: a first recess for receiving and positioning the cable end piece, a second recess for visual inspection of the connection, and a third recess for receiving and transmitting solder. This segmentation allows each recess to perform a specific function, simplifying the overall soldering process while maintaining connection quality
Solution Approach 2:
The soldering aid enables preliminary positioning and fixation of the cable strand and contact structure before actual soldering occurs. The first recess pre-positions the cable end piece, and the contact structure is preliminarily fixed to the insulating body, so that when solder is applied, the components are already in their correct positions, reducing the time and complexity of the soldering process
2Reliability
If the contact structure is fully embedded in the insulating body for secure connection, then connection stability is improved, but visual inspection of the connection becomes difficult
Solution Approach 1:
The second recess extracts or opens into the insulating body to provide a viewing window that allows visual inspection of the connection between the stranded wire and contact structure. This extraction creates an optical path through the insulating material, enabling quality control without compromising the embedded connection stability
Solution Approach 2:
The second recess acts as an intermediary medium that allows light to pass through the insulating body to visualize the internal connection. It serves as a mediator between the embedded contact structure and the external inspector, enabling detection without exposing the connection
3Manufacturing precision
If the first recess is designed to receive both stripped and non-stripped parts of the cable, then the positioning accuracy is improved, but the recess design becomes more complex
Solution Approach 1:
The first recess is designed with different local qualities or sections: a first section for receiving the non-stripped cable end piece and a second section for receiving the stripped cable end piece with the stranded wire. Each section has specific geometric characteristics suited to its function, allowing precise positioning of different cable portions without requiring multiple separate components
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
Simplifies the soldering process by guiding and fixing the cable strand, providing a visual check for correct positioning, and ensuring a permanent, non-detachable connection between the cable and the circuit board, reducing the complexity and time required for cable connection.
Implementation Method 1
The third recess is spatially offset from the first recess and the second recess and its end borders on the second section of the first recess, wherein the third recess is designed to receive and transmit solder into the second section of the first recess in order to form the connection between the stranded wire and the contact structure there
Implementation Method 2
an electrically conductive contact structure coupled to the body. The contact structure is partially embedded in the body in order to be connected to a stranded wire of the cable inside the body, and partially protrudes from the body in order to be connected to a terminal of the printed circuit board
Data Source
Figure 1
Figure 2
AI summary
A soldering aid (100) for connecting a cable (200) to a printed circuit board (300) comprises: an electrically insulating body (190) with a first recess (110), a second recess (120), and a third recess (130); and an electrically conductive contact structure (150) coupled to the body (190). The contact structure (150) is partially recessed into the body (190) to connect to a strand (210) of the cable (200) inside the body (190) and partially protrudes from the body (190) to connect to a terminal (310) of the printed circuit board (300).