Soldering Anvil Insulation via Nesting and Intermediary
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Solution Overview
Problem
Existing soldering devices for electrical conductors face issues with electrical leakage and arcs due to anvil insulation deterioration and mechanical stress, leading to inefficient heat concentration and reduced device lifespan.
Innovation Solution
The device incorporates an anvil with a supplementary insulating coating and a through-hole design, where the anvil is partially housed in the base plate, using insulating glue to fix and isolate the anvil, reducing electrical leakage and improving heat concentration at the contact area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the anvil is placed on the surface of the base plate, then the device structure is simpler, but the anvil may deviate from its initial fixing position and cause electrical leakage or arcs
Solution Approach 1:
The anvil is housed within a through-hole of the base plate, nesting the anvil inside the base plate structure. This prevents the anvil from deviating horizontally and maintains stable electrical insulation, resolving the contradiction between simple structure and reliable insulation.
Solution Approach 2:
An insulating element is introduced as an intermediary between the anvil and the base plate. This mediator provides continuous electrical insulation and prevents arcs, while the through-hole provides mechanical constraint, together resolving the reliability issue without significantly increasing complexity.
2Productivity
If high electrical current is applied to reach soldering temperature, then the soldering process is effective, but electrical leakage and arcs increase due to insulation deterioration
Solution Approach 1:
The insulating element is installed beforehand to cushion against electrical leakage and arcs before they can occur. This preventive measure allows high current to be applied safely for effective soldering without the harmful effects of insulation deterioration.
Solution Approach 2:
The insulating element acts as an intermediary that blocks the path of electrical leakage and arcs between the anvil and base plate. This mediator enables high current application for productive soldering while preventing harmful electrical discharge.
3Reliability
If the anvil is housed in a through-hole with insulating glue, then electrical insulation and positional stability are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The through-hole structure combines multiple functions: mechanical constraint (preventing horizontal movement), electrical insulation (blocking current leakage), and positional alignment. This merging of functions improves reliability without proportionally increasing manufacturing complexity.
Solution Approach 2:
The insulating element serves multiple purposes simultaneously: providing electrical insulation, preventing arcs, and maintaining positional stability of the anvil. This multi-functionality improves reliability while minimizing the increase in manufacturing complexity.
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 solution effectively reduces electrical leakage and arcs, enhances heat concentration at the soldering contact area, and increases the device's stability and lifespan by providing robust electrical insulation.
Implementation Method 1
the heat necessary to create the solder is generated by Joule effect at the junction of the electrical connector and the connection device towards the top of the anvil
Implementation Method 2
the anvil being at least partially housed in the hole makes it possible to improve the stability and the robustness of the device for soldering... the glue makes it possible, on the one hand, to fix the anvil to the base plate and, on the other hand, to electrically insulate the anvil from the base plate
Data Source
Figure 1a
Figure 1b
Figure 2a~2b
AI summary
The present invention relates to a device for soldering an electrical conductor with a connection device, comprising a base plate (23, 223) on which an anvil (19, 219) is mounted, the anvil (19, 219) making it possible to pass an electrical current (I) through the electrical conductor and/or the connection device (11, 211), such that the anvil (19, 219) is at least partially housed in a through-hole (25, 225) of the base plate (23, 223) and arranged to be electrically insulated from the base plate (23, 223). The present invention also relates to a device for soldering an electrical conductor with a connection device, comprising an anvil (119, 229) with an electrical contact area (115, 215)towards the top (117, 217) of the anvil (119, 219) on which the electrical conductor and the connection device (111, 211) are intended to be placed, the anvil (119, 219) being capable of making an electrical current (I) circulate through the electrical conductor and the connection device (111, 211); and a cutting unit (150, 250) capable of cutting a portion (151, 251) of the connection device (111, 211) towards the top (117, 217) of the anvil (119, 219); such that the anvil (119, 219) and the cutting unit (150, 250) are at least partially distanced from each other at least at the top (117, 217) of the anvil (119, 219) in order to electrically insulate them from each other. The present invention also relates to a device for soldering comprising an anvil (19, 119, 219) and/or a deformation unit (13, 113, 213, 313) at least partially covered with an electrically insulating coating by physical vapour deposition, in particular by a ceramic layer of 12 micrometers thickness.