PCB Tin Contact Point for Vibration-Resistant Vehicle Connections
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Solution Overview
Problem
Existing electrical contacts in vehicles face challenges in terms of vibration resistance and durability due to additional production and material costs associated with contact plates, which are used to establish electrical connections between components.
Innovation Solution
A printed circuit board with a contact point featuring a support element made of tin, which is soldered using a reflow method, ensuring a height of 50 to 150 micrometers to withstand vibrations and shocks, and integrated with a contact spring for secure electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a contact plate is used to establish electrical connections, then conductivity and resistance to abrasion are improved, but production costs and material costs increase
Solution Approach 1:
The invention extracts the essential function of the contact plate (providing a conductive, abrasion-resistant surface) and implements it directly through the support element made of tin or tin alloy, eliminating the need for a separate contact plate component. This reduces both material costs and production complexity while maintaining the required conductivity and wear resistance.
Solution Approach 2:
The invention merges the functions of the support element and contact plate into a single integrated structure. The support element itself provides the conductive surface for electrical contact, combining structural support and electrical contact functions that were previously separated into distinct components, thereby reducing overall system cost and complexity.
2Reliability
If a contact plate is used for electrical contacting, then durability is improved, but device complexity increases
Solution Approach 1:
The invention removes the separate contact plate component from the assembly, extracting only the essential contact function and integrating it into the support element. This simplifies the device structure by reducing the number of discrete components while maintaining durability through the use of appropriate materials and design.
Solution Approach 2:
The support element is designed to perform multiple functions simultaneously: providing mechanical support, enabling electrical contact, and ensuring durability through vibration resistance. This multi-functional design eliminates the need for separate specialized components, thereby reducing device complexity.
3Manufacturing precision
If reflow method is used to solder the support element, then manufacturing precision is improved, but flux residue may occur
Solution Approach 1:
The invention modifies the reflow soldering parameters, specifically controlling the heating profile and temperature range to optimize the melting and flow of the tin support element while minimizing flux decomposition and residue formation. This parameter optimization maintains high soldering precision while reducing harmful flux residue.
Solution Approach 2:
The invention converts the potential harm of flux residue into a benefit by carefully controlling the reflow process to ensure complete flux evaporation or decomposition, transforming the flux from a source of contamination into a useful agent that enables proper soldering without leaving harmful residues.
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 solution provides cost-effective, vibration-resistant electrical connections with improved durability and conductivity, eliminating the need for additional components and method steps, while preventing flux residue and oxidation.
Implementation Method 1
the contact point has a support element of tin which by a reflow method is soldered to the printed circuit board
Implementation Method 2
the solder paste is melted while component parts of the flux are extracted as gas
Implementation Method 3
Surface tension effects adjust the SMDs which are fixed by the cooled solder
Data Source
AI summary
A printed circuit board, including: a contact point for contacting; a contact spring for an electrical contact in a vehicle; in which the contact point has a support element of tin that is reflow soldered to the printed circuit board. Also described are a related module and method.