Press-in Bolt for Non-Solderable Materials
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Solution Overview
Problem
Existing methods fail to produce reliable and cost-effective electrical connections between solderable and non-solderable materials, which are crucial in applications like mobile communications technology where intermodulation-stable connections are necessary.
Innovation Solution
The use of press-in bolts made of solderable material, which are pressed into non-solderable strip or plate-shaped materials to create a hole with a broken circumferential rim, providing a strong press-fit and deformation that acts as a soldering point, and optionally featuring knurling for enhanced grip and intermodulation prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to create electrical connections, then electrical conductivity is improved, but it cannot be applied to non-solderable materials such as certain strip conductors and metal sheets
Solution Approach 1:
The patent introduces a press-in bolt as an intermediary component that mechanically and electrically connects solderable and non-solderable materials. The bolt is pressed into the non-solderable strip conductor or metal sheet, creating a press-fit connection that provides both mechanical anchoring and electrical conductivity, thereby enabling connection where traditional soldering cannot be applied.
Solution Approach 2:
The patent replaces the thermal-chemical soldering process with a mechanical press-fit system. Instead of using heat and molten solder to create joints, the invention uses a pressing tool to force the press-in bolt into the non-solderable material, creating a secure mechanical connection that also provides electrical conductivity through direct metal-to-metal contact.
2Adaptability or versatility
If press-in connections are used to connect to non-solderable materials, then material compatibility is improved, but connection stability and electrical conductivity may be insufficient
Solution Approach 1:
The press-in bolt functions as a composite connection element that combines multiple functional properties: it provides mechanical anchoring through press-fit into the non-solderable material, electrical conductivity through its conductive material composition, and structural support through its rigid form. This single component integrates what would otherwise require separate elements.
Solution Approach 2:
The pressing tool features a conical or tapered pressing face that concentrates the pressing force onto a small area of the press-in bolt head. This geometric design ensures uniform distribution of force during the pressing operation, preventing deformation of the bolt while achieving secure insertion into the non-solderable material.
3Strength
If knurling is added to the press-in bolt for enhanced grip, then mechanical strength is improved, but manufacturing complexity increases
Solution Approach 1:
The knurling process modifies the surface parameters of the press-in bolt by creating a pattern of raised ridges and valleys. This surface texture increase the friction between the bolt and the non-solderable material, significantly improving grip and press-fit strength. The knurling can be applied through various manufacturing methods including rolling, stamping, or extrusion, making it compatible with standard production processes.
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 enables the creation of stable and intermodulation-free electrical connections by ensuring a robust press-fit and self-cleaning effect, even with thin metal sheets, and is suitable for various conductive materials including coaxial cables.
Implementation Method 1
pressed into non-solderable strip or plate-shaped materials to create a hole with a broken circumferential rim, providing a strong press-fit and deformation
Implementation Method 2
optionally featuring knurling for enhanced grip and intermodulation prevention
Implementation Method 3
press-in bolts made of solderable material, which are pressed into non-solderable strip or plate-shaped materials to create a hole
Data Source
AI summary
This invention relates to an electrical connection device on a plate-type or strip-type material (1, 1′), which cannot be soldered or is difficult to solder or which is provided with a surface that cannot be soldered or is difficult to solder, having the following characteristics: A self-clinching bolt (5) is provided with a bolt head (7) that, relative to the bolt body (9) beneath, has a tapered cross section such that the bolt head (7) transitions, by way of a conical or shoulder-like sloping flank (11), into the bolt body (9) having an outer circumference (9′) that has a diameter larger than that of the bolt head (7). The outer circumference (9′) of the bolt body (9) is of smooth design, or is provided with a knurling (15). In the penetration area of the self-clinching bolt (5), the plate-type or strip-type material (1, 1′) is provided with a non-flanged material edge (101). Within the material edge (101), the self-clinching bolt (5) is press-fit with a peripheral area of the bolt body (9) thereof, thus creating a force fit.