Combined Reflow Soldering for PCB Contact Bushings
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Solution Overview
Problem
The existing methods for connecting sensors and actuators to printed circuit boards in the automotive industry require two separate working steps, involving soldering components and then attaching a synthetic guide strip, which is inefficient and costly.
Innovation Solution
A method using a reflow soldering process to combine the soldering of electronic components and contact bushings on a printed circuit board in a single step, eliminating the need for a separate guide strip and reducing the number of working steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate working steps are used to solder components and attach guide strip, then reliable electrical connections are achieved, but manufacturing complexity and production time increase
Solution Approach 1:
The patent combines the soldering of electronic components and the attachment of contact bushings into a single reflow soldering process. The contact bushings are positioned on the printed circuit board before the reflow soldering step, allowing both the components and contact bushings to be permanently attached simultaneously through one heating cycle that melts the solder paste and creates reliable electrical connections.
Solution Approach 2:
The reflow soldering process is used to achieve multiple functions simultaneously: it serves both to solder the electronic components to the printed circuit board and to permanently attach the contact bushings. This multi-functional approach eliminates the need for separate selective soldering and guide strip attachment steps.
2Manufacturing precision
If two separate working steps are used for component soldering and guide strip attachment, then proper positioning is achieved, but production efficiency decreases
Solution Approach 1:
The contact bushings are positioned on the printed circuit board in advance during the component placement step, before the reflow soldering process. This preliminary positioning allows the bushings to be correctly located alongside the electronic components, and both are then permanently fixed in a single reflow soldering operation, improving production efficiency without sacrificing positioning accuracy.
3Manufacturing precision
If synthetic guide strip is used for contact pin guidance, then contact pin positioning is achieved, but additional materials and costs are required
Solution Approach 1:
The patent eliminates the synthetic guide strip from the contacting arrangement by integrating the positioning function directly into the printed circuit board structure. The contact bushings are mounted on the PCB and provide the necessary guidance and positioning for contact pins without requiring an additional synthetic material layer, thereby reducing material usage and costs.
Solution Approach 2:
The contact bushings serve multiple functions: they provide mechanical support for contact pins, guide pin insertion, establish electrical connections, and eliminate the need for separate synthetic guide strips. This multi-functional design reduces the quantity of materials required while maintaining positioning precision.
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 approach minimizes the number of working steps, reduces costs, and allows for a more compact design with automatic placement of contact bushings, providing reliable electrical connections for sensors and actuators.
Implementation Method 1
combined soldering the at least one component to the printed circuit board and the contact bushing to the printed circuit board in one method step. The actuator can be for example a controllable valve (e.g. solenoid valve). The combined soldering process is in particular a reflow soldering process.
Implementation Method 2
The soldering means can be embodied for example in the form of pads around the opening and melts during the exemplary reflow soldering process.
Data Source
AI summary
A method for producing a connection contact for a sensor or an actuator of a vehicle, the method including: providing a printed circuit board having at least one electronic component arranged thereon and having an opening; inserting a contact bushing into the opening; and combined soldering the at least one component to the printed circuit board and the contact bushing to the printed circuit board in one task. Also described are a related circuit board and a vehicle control unit.