Radial Multi-Point Solder Tip for Simultaneous PCB Lead Joining

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Solution Overview

Problem

Current soldering processes for attaching wires to a printed circuit board assembly (PCBA) require a skilled workforce and are time-consuming, necessitating individual soldering of each lead, which can be inefficient and costly.

Innovation Solution

A multipoint radial soldering tip with thermally conductive and corrosion-resistant components, featuring multiple soldering feet arranged radially, allows for parallel soldering of multiple leads simultaneously, facilitated by a robot-controlled system for improved speed and accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If individual soldering of each lead is performed manually, then soldering quality can be maintained, but manufacturing time increases and productivity decreases

Engineering Contradiction:

Improvesoldering qualityVSAvoidmanufacturing speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent combines multiple soldering feet (at least three) onto a single soldering tip, allowing simultaneous contact with multiple leads on the PCBA. This merging of multiple soldering functions into one tool enables parallel soldering operations, dramatically increasing productivity while maintaining consistent soldering quality through uniform temperature distribution across all feet.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The soldering tip is segmented into multiple independent soldering feet arranged radially, each capable of contacting a separate lead. This segmentation allows each foot to independently transfer heat to its corresponding lead while being part of a unified thermal system, enabling simultaneous soldering of multiple joints without compromising individual joint quality.

Inventive Principle:

Principle #1Segmentation

2Productivity

If multiple leads are soldered simultaneously using a multipoint radial soldering tip, then productivity increases and manufacturing time decreases, but device complexity increases

Engineering Contradiction:

Improvemanufacturing speedVSAvoidsoldering tip structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The multipoint radial soldering tip serves multiple functions simultaneously: it provides mechanical support for multiple soldering feet, conducts heat uniformly across all feet through its thermally conductive body, and maintains precise spatial positioning of each foot relative to the PCBA solder pads. This multi-functionality is achieved through an integrated design where the tip body and feet form a unified thermal and mechanical system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The soldering tip body acts as an intermediary that distributes thermal energy from a single heat source (the soldering iron contact point) to multiple soldering feet. This intermediary structure ensures uniform temperature distribution across all feet while mechanically coupling them to the heat source, simplifying the overall system by requiring only one heat source instead of multiple independent soldering tools.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If manual soldering is performed, then flexibility and adaptability are maintained, but labor costs increase and consistency decreases

Engineering Contradiction:

Improveprocess flexibilityVSAvoidsoldering time per unit

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The multipoint radial soldering tip is designed to be self-positioning through its radial arrangement of feet that naturally align with pre-defined solder pad locations on the PCBA. The wire comb component also provides self-alignment features that guide the soldering tip into the correct position, reducing the need for manual positioning adjustments and enabling consistent, repeatable soldering operations.

Inventive Principle:

Principle #25Self-service

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 system reduces manufacturing time and increases joint quality, providing significant cost savings and enhanced productivity through simultaneous soldering of multiple leads, while maintaining precise positioning and temperature control.

Implementation Method 1

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20260048447A1Radial multi-point solder tip and related solder device

Publication Date: 2026.02.19 VERTIV IT SYST INC

AI summary

In an embodiment, a soldering tip is configured for a number of solder pads at a number of radial locations and includes a soldering head, a shank, and a number of soldering feet. The soldering head is made of a thermally-conductive, corrosion-resistant material. The soldering head defines an upper head surface and a curved forward extension, the curved forward extension descending from the upper surface. The curved forward extension is lengthwise convexly curved and defines an extension face obverse to the upper head surface. The shank is coupled to the upper head surface of the soldering head and is configured to operatively couple with a soldering iron. The shank is made of a thermally conductive material. The soldering feet are operatively coupled to and protrude from the extension face. The soldering feet are configured to transfer bonding energy to the corresponding solder pads.