Wire-to-Solder Joint Adapter With Air-Escape Venting
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Solution Overview
Problem
Conventional adapters for coupling wires to solder joints are costly, cumbersome, and inefficient.
Innovation Solution
An adapter with a solder joint receiving hole and a wire attachment terminal, designed to facilitate detachable coupling using a crimping connector or screw, allowing for efficient and cost-effective connection of wires to solder joints, even in components with non-threaded holes, and featuring an air-escape hole to prevent air entrapment during soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional adapters are used to couple wires to solder joints, then connection reliability is achieved, but cost and device complexity increase
Solution Approach 1:
The adapter is divided into distinct functional segments: a body portion with a receiving hole for the solder joint, and a separate wire attachment terminal. This segmentation allows each part to be optimized independently while maintaining overall reliability, reducing the complexity of any single component.
Solution Approach 2:
The adapter serves as an intermediary component between the solder joint and the wire. By introducing this intermediate element, the patent enables reliable electrical connection without requiring direct soldering to the component lead, simplifying the overall assembly process while maintaining connection reliability.
2Reliability
If conventional adapters are used to couple wires to solder joints, then electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The adapter is designed as a simple, inexpensive component that can be easily manufactured and replaced if necessary. The use of basic materials and straightforward construction methods keeps manufacturing costs low while ensuring adequate electrical connection reliability for the application.
Solution Approach 2:
The adapter incorporates self-aligning features and intuitive attachment mechanisms that reduce the need for complex assembly tools or specialized manufacturing processes. The wire attachment terminal is designed to accept wires through simple insertion and crimping, eliminating the need for expensive specialized equipment.
3Reliability
If conventional adapters are used to couple wires to solder joints, then connection is achieved, but efficiency and ease of operation decrease
Solution Approach 1:
The wire attachment terminal is designed with dynamic attachment characteristics, allowing for easy insertion and secure locking. The terminal can accommodate slight variations in wire positioning while maintaining reliable electrical connection, and allows for efficient assembly through simple crimping or screw fastening without requiring precise alignment.
Solution Approach 2:
The adapter body is pre-formed with the receiving hole and wire attachment terminal in positions that facilitate easy assembly. The receiving hole is pre-positioned to align with typical solder joint locations, and the wire terminal is pre-configured to accept standard wire gauges, eliminating the need for complex positioning or adjustment during assembly.
4Manufacturing precision
If soldering is performed without air escape path, then solder joint is formed, but air entrapment occurs causing defects
Solution Approach 1:
An air escape hole is provided in the adapter body to extract trapped air during the soldering process. This extraction of air prevents air entrapment defects in the solder joint while maintaining the integrity and quality of the solder connection. The air escape hole is strategically positioned to allow air to escape without compromising the electrical connection.
Data Source
AI summary
Embodiments of the present disclosure may comprise an adapter to couple a wire to a solder joint, with the adapter comprising a solder joint receiving hole and a wire attachment terminal.