Plate Element Conductor Layout Without Soldered PCB Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of printed circuit boards for electrical heating devices is expensive and limits adaptability to different heating circuits, with soldered connections that complicate manufacturing and restrict operating temperature.
Innovation Solution
A method involving stamping or stamping-bending of metal plates to form conductor tracks and contact tongue receptacles, which are then joined with a non-conductive plastic carrier plate via injection molding, allowing for easy electrical insulation and mechanical fastening without soldering, enabling flexible circuit formation and higher temperature exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If printed circuit boards with soldered connections are used, then electrical connections are permanent and reliable, but manufacturing becomes complex and operating temperature is limited
Solution Approach 1:
The patent replaces the soldering process (thermal-chemical mechanical system) with a mechanical press-fit connection system. Contact tongue receptacles are formed as recesses in the plate element that mechanically receive and secure contact tongues through friction and geometric interlocking, eliminating the need for soldering while maintaining reliable electrical connections.
Solution Approach 2:
The patent extracts the soldering operation from the manufacturing process entirely. By designing contact tongue receptacles that are integrally formed with the plate element body, the connection structure is simplified to require only mechanical insertion and pressing, removing the complex multi-step soldering process while preserving connection reliability.
2Stability of the object's composition
If printed circuit boards with permanently specified conductor tracks are used, then electrical connections are stable, but adaptability to different heating circuits is limited
Solution Approach 1:
The patent introduces dynamic reconfigurability to the electrical connection system. Contact tongues can be selectively connected to different conductor tracks through the plate element's internal routing, allowing the heating circuit configuration to be changed by rearranging contact tongue positions or connections, while the physical plate structure remains stable and permanent.
Solution Approach 2:
The patent segments the electrical connection function into separate modular components: the plate element with integrated conductor tracks, and removable contact tongues that can be independently positioned and connected. This segmentation allows different combinations of contact tongues to be connected to different conductor tracks, providing adaptability while maintaining structural stability.
3Reliability
If contact tongue receptacles are soldered onto the printed circuit board, then electrical connections are permanent, but manufacturing cost increases and operating temperature is restricted
Solution Approach 1:
The patent merges the contact tongue receptacles with the plate element body into a single integral structure. The receptacles are formed directly in the plate element during the same manufacturing process, eliminating the need for separate soldering operations and reducing manufacturing steps, cost, and time while maintaining permanent mechanical and electrical connections.
Solution Approach 2:
The patent replaces the soldering mechanical system with a mechanical press-fit connection system. Contact tongues are secured through friction-fit recesses and geometric interlocking features formed in the plate element, providing permanent connections without thermal processes, reducing manufacturing complexity and enabling higher operating temperatures.
4Reliability
If conventional plate elements with soldered connections are used, then electrical connections are reliable, but production time and cost increase
Solution Approach 1:
The patent performs preliminary action by pre-forming the contact tongue receptacles as integral features of the plate element during its primary manufacturing process. This preliminary formation of connection receptacles eliminates the need for subsequent soldering operations, reducing production time and increasing manufacturing efficiency while maintaining reliable electrical connections.
Solution Approach 2:
The patent combines multiple manufacturing operations into a single integrated process. The plate element is manufactured with conductor tracks and contact tongue receptacles formed in the same production cycle, eliminating separate soldering steps and reducing overall production time, cost, and complexity while ensuring reliable electrical connections.
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 method simplifies the production of plate elements with conductor tracks, reduces costs, and allows for adaptable heating circuits and higher operating temperatures by eliminating the need for soldering and using inexpensive materials, while ensuring secure and efficient electrical connections.
Implementation Method 1
which is produced by means of injection molding from plastic
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to a method for manufacturing a plate element (1) having conductive traces, in which a carrier plate (20) is produced from plastic by injection molding, a metal plate (10) is stamped to form surface elements (11.1 - 11.5) connected to one another via connecting webs (12) and contact tongue receptacles (13; 15) provided in the surface elements (11.1 - 11.5), the carrier plate (20) and the metal plate (10) are joined, and subsequently the connecting webs (12) are cut. The present invention aims to provide a simplified method for manufacturing a plate element having conductive traces.