Solderable Electric Connection Element With Back-to-Back Crimping
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Solution Overview
Problem
Existing solderable electrical connection elements face issues with solder penetration into the crimping portion during the soldering process, leading to cable stiffening and fracture risks, as well as contamination of the crimping portion by flux agents, due to the shared surface area and lack of separation between crimping and soldering portions.
Innovation Solution
A solderable electrical connection element with a crimping portion and a soldering portion separated by a transition portion, where the soldering portion is positioned on top of the crimping portion after a creasing process, and features lateral prongs for direct soldering access and mechanical fixation, preventing solder penetration and flux contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the crimping portion and soldering portion are arranged in one plane to simplify manufacturing, then the device complexity is reduced, but the surface area occupied increases and solder may penetrate into the crimping portion
Solution Approach 1:
The soldering portion is folded back onto the crimping portion using a crease, transitioning from a planar two-dimensional arrangement to a three-dimensional stacked configuration. This dimensional change reduces the occupied surface area while maintaining manufacturing simplicity through the folding process
2Ease of manufacture
If the crimping portion and soldering portion are arranged in one plane, then manufacturing is simplified, but solder penetration into the crimping portion occurs during soldering
Solution Approach 1:
By folding the soldering portion back onto the crimping portion through a crease, the soldering surface is positioned in a different spatial plane away from the cable end. This prevents solder from flowing into the crimping portion during the soldering process, maintaining cable integrity while preserving manufacturing simplicity
3Ease of manufacture
If the crimping portion and soldering portion share the same surface area, then manufacturing is easier, but flux contamination of the crimping portion occurs
Solution Approach 1:
The crease folds the soldering portion back so that the flux application area is spatially separated from the crimping portion. Flux can now be applied locally to the soldering surface without contaminating the cable end or crimping area, maintaining manufacturing ease while eliminating contamination risks
4Area of stationary object
If the soldering portion is folded back onto the crimping portion, then the occupied surface area is reduced, but the device complexity increases
Solution Approach 1:
The connection element is segmented into distinct functional zones separated by a crease: the crimping portion for mechanical cable attachment and the folded-back soldering portion for electrical bonding. This segmentation allows compact spatial arrangement while maintaining clear functional separation through simple geometric division
5Reliability
If the soldering portion is folded back onto the crimping portion, then solder penetration is prevented, but manufacturing complexity increases
Solution Approach 1:
The crease is pre-formed during manufacturing to create the folded-back configuration before the soldering process. This preliminary structural preparation ensures that during subsequent soldering operations, the soldering surface is already positioned away from the cable end, preventing solder penetration without adding complexity to the soldering process itself
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 reduces surface area occupation, prevents solder penetration into the crimping portion, minimizes flux contamination, and allows for efficient soldering with reduced material heating, enhancing mechanical stability and process efficiency.
Implementation Method 1
a crease is configured in the transition portion (6) so that the crimping portion (1) and the soldering portion (2) assume a back-to-back position as a result of a bending step
Implementation Method 2
the soldering portion (2) directly adjoins the crimping portion (1) or is offset from the crimping portion (1) by a transition portion (6)... prevents solder penetration into the crimping portion
Data Source
AI summary
The invention relates to a solderable electric connection element including a crimping portion for receiving a connection cable and a soldering portion for bonding to the surface of an electrically conductive structure. The soldering portion directly adjoins the crimping portion or is offset therefrom by means of a transition portion, and a solder deposit is provided or can be placed on the solder region. According to the invention, an angled section is formed in the section between the crimping and soldering region or in the transition region such that the crimping and soldering region are arranged in a back-to-back position, wherein the free face of the soldering region receives the solder deposit.