Solderless FPCB Connector Structure for Reliable Battery Module Assembly
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Solution Overview
Problem
Conventional FPCB connectors require soldering, which complicates the process, increases costs, and results in high defect rates, making them inefficient and costly.
Innovation Solution
A FPCB connector design that allows coupling of FPCBs without soldering, using a first main body with an insert groove and fixing portion, and a second main body with a coupling groove and terminal members for electrical connection, enabling secure attachment without soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If soldering is used to couple FPCB to connector, then connection strength is improved, but process complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical system) with a mechanical pressing and locking system. The pressing member applies force to deform the FPCB contact portion, which then engages with the connector's locking structure through elastic deformation, eliminating the need for soldering while maintaining connection strength.
Solution Approach 2:
The patent utilizes elastic deformation as a key parameter change mechanism. The FPCB contact portion is designed to elastically deform under pressing force, transforming from a rigid state to a flexible engaged state, enabling secure mechanical connection without thermal processes.
2Reliability
If soldering is used to couple FPCB to connector, then connection reliability is improved, but productivity deteriorates due to high defect rate
Solution Approach 1:
The mechanical pressing and locking mechanism eliminates soldering defects such as cold joints, bridging, and insufficient wetting. The connection is established through controlled elastic deformation and mechanical interlocking, which are more reliable and easier to control automatically, thereby improving both reliability and productivity.
Solution Approach 2:
The FPCB contact portion serves dual functions: it provides both the electrical connection path and the mechanical locking feature through its elastic deformation. This self-locking mechanism eliminates the need for separate soldering and mechanical fastening steps, improving productivity while maintaining reliability.
3Reliability
If soldering is used to couple FPCB to connector, then electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The patent eliminates soldering materials (flux, solder wire, solder paste) and associated equipment costs by using a purely mechanical connection system. The FPCB's own structural features are utilized for both electrical conduction and mechanical locking, reducing material costs and simplifying manufacturing equipment requirements.
Solution Approach 2:
The FPCB contact portion is designed to perform multiple functions simultaneously: electrical conduction, mechanical support, and self-locking. This multi-functionality eliminates the need for separate components and processes, reducing overall manufacturing cost while maintaining electrical connection reliability.
Data Source
AI summary
A FPCB connector including a first main body to which a first FPCB is coupled, and a second main body to which a second FPCB is coupled, the second main body being coupled to and electrically connected to the first main body. At least one of the first main body and the second main body is coupled to the first FPCB or the second FPCB without soldering.