Redesigning the soldering iron!

#1
Hi, we’re a team of engineering undergrads hoping to redesign the soldering iron. Specifically, we’re looking at making it safer and more usable by younger teens and children.

We’re looking for any feedback or advice you might have, especially if you have kids, so if you can spare a few minutes to fill out our survey, that’d be awesome. Or if you have any questions, feel free to shoot us an email at: [email protected]. Thank you for your time and input!

https://docs.google.com/forms/d/14cAsPIbiU_jf09aFBU03nplbYuBtr0JpTPzrWEp4OFw/viewform

also, does anyone know why there is so much metal exposed towards the tip?
 
#2
Just a quick idea. maybe you could design a heat resistant sleeve that is spring loaded to slide down over the hot shaft and point when not in use. You would need to figure out a way to keep it up during use and make that safe, quick, and easy to do. Doing something like this would make it safer for young adults as well as allowing it to be laid down on a table or work bench during use (when it is on) with less of a fire hazard.
 
#4
A heatsink and a thermal mass. I've always felt that it should be insulated anyway but this would require expensive materials to accomplish. basically you want to change the fact that it is a 10" stick that has 6 inches of scorching hot metal ready to start fires or cauterize pubescent acne. my suggestion is to start with a digitally controlled soldering iron that has interchangeable tips. At work I used the pace heatwise pw100, I think it would be a good candidate as the temperature control is in the base not the tip itself making the tips cheaper. the handle could be wrapped with fiberglass and epoxy for insulation as it does get hot and the tips could have a sleeve machined out of ceramic such as that used on space shuttle tiles. A retrofit kit would be a cheaper option than designing an iron from the ground up. by having this sleeve in place it limits the amount of exposed hot metal, another approach to this would be making the tip itself smaller. I have a radioshack portable soldering iron with a removable tip that is about 3/4" long. it runs on aa batteries. I have also added a coax jack so I could plug it into a 5v line from a pc psu. The problem with a tip that is smaller is that the heat capacity will be too small for a lot of solder work.

My conclusion is that you need a sleeve with a set screw. the sleeve will be expensive so the set screw would allow you to put it on different tips as they wear out or others are needed. Just realize the heat will want to go somewhere and having a good handle as well as lowering the temperature would help a lot. Temperature controlled models will self adjust and become more efficient.
 
#5
Just realized your handle may end up melting as that "heatsink" wont be there anymore allowing more heat to reach the handle. Have fun burning yourself, it will happen.
 
#6
If a first time user doesn't get a burn, then how are they to know which end to hold? ;)

Stop wrapping kids in bubble plastic, it will only weaken them!
 
#8
I got that, I just don't see why?

Although I am not to keen on solderless breadboards for serious stuff, they're absolutely perfect for teaching electronics to kids and after all, it's not about teaching them how to solder (they can pick that up later), but rather about teaching them fundamental electronics principles - and they have to be of a certain age to be able to understand that anyway, as they need the ability of abstraction. Until they develop abstract thinking, you can only get them familiarized with components and perhaps help them build something that attracts their attention and interest.

http://www.learningrx.com/4-cognitive-stages-for-child-development-faq.htm said:
At age 7 to age 12, children begin to understand logical or rational thought, but only concretely — in relationship to things they can see or touch. They are also noticeably better at seeing another’s point of view and considering others’ feelings. From the age of 12 on, the person beings to develop abstract reasoning skills and can think logically and rationally, without having to depend on visual or tactile aids. Complex abstract thought is now possible, and cognitive development is complete.
I did help my sons build a discrete astable with LEDs each, when they where 5 and 8 years old respectively. I showed them how to solder the components and they did - and they were very proud of their outcome, but they didn't understand anything besides that a battery could make the LEDs flash of course.


Regardless of whether or not we should "bubble wrap them" a lot of parents won't let their kids do this sort of activity with the current risk and if a child got hurt there would unfortunately be lawsuits. At the same time I think designing such a soldering iron and giving it to a child would be mostly pointless. I don't think a child that couldn't handle a regular soldering iron would be able to understand most of the concepts you would hope to teach.
I'm so happy that I don't live in the Land of Litigation - must be awful (if you're not a lawyer) having to always fear, that trying to do good may cost you dearly.
And I agree, that they won't be able to do much - except that anyway a "secure" soldering iron was made, some of the kids would find a way to let's say "use it outside it's recommended scope".

I'm sure the OPs mean well, but it appears that they either didn't think it through or didn't have the knowledge - my recommendation to them would be to make a better solderless breadboard instead (and there's so many ways they could be improved).


As an aside, hand soldering as we know it, is likely not here for generations on - it's a matter of time before you 3D print an "assembled" board. First the printers will have pick 'n' place ability, but at some point in time you'll be able to "print" semiconductors as well - and no, I'm not betting on when :)

I made a bet on LED technology some 14..15 years ago in a Danish newsgroup, where a lot of punks with semi-knowledge and the optimism of youth, declared "in 10 years, all lightning will be made with LEDs" - well, none of them were to find, when I wanted to cash in on the steak and red wine, so no point in foretelling the future :D
 
#10
Oh, there are good as well as bad sides to any country and knowing how to navigate is key.
I once worked with a girl originally from Sri Lanka, who told me of their gigantic python they had as a pet animal (I'd run away screaming if it was me) - she was terrified of walking around the streets of Copenhagen due to the traffic - it all depends on your "programming" I think.

While on the subject and risking to be misunderstood, i will relay the first impressions from a friend who married an US citizen and now teaches at some university on the east coast.
She was flabbergasted over the lack of self motivation/drive in the semi-adults in her classes, where she had to instruct them in detail on everything they needed to do and she compared them to 12-year old Danish kids in that respect (and she teaches foreign language, not Danish though, but no technology at all).

I'm sure there are some cultural differences at play in this and while religion may be a root cause of some of the technology oriented resistance, perhaps many are simply being babied to proportions where they don't develop all that much independence until later (if ever, the childhood and youth is where the adult is founded after all).
This would also explain another trait I see in many (most?) US citizens, the extreme nationalism that amongst other things gives the armed forces all the resources they want, with very little real questions asked and the (from my standpoint) exorbitant respect/honour giving to people that is or has been part of said forces - and quite frankly, nationalism is counterproductive with regards to the global village - I really couldn't care less when some religious nutters of a south-eastern persuasion started burning Danish flags (hey, a cloth is a cloth) either, but it seems to really infuriate US citizens.

Then again, this may seem a strange way of viewing to you. A guy I used to know in Kuala Lumpur, Malaysia told me he studied to become a lawyer. I told him he'd surely become a fine politician within a short time and that offended him, as he said that politicians was loathed there (and all crooked). Here, our politicians are generally respected, even the ones we disagree with :)

I'm sure we see things depending on where and how "our eyes" were raised, so there will be differences (to the end of eternity) and the best we can hope for is acceptance of these differences.

Oh, that was a side track... but to be at least a little bit on topic - don't put anything hotter than ~50°C in the hands of children, or they will hurt or get hurt, no matter how much safety is involved - gee, how did we survive our childhood - no cell phones to call home and plenty of sharp objects like scissors (which will now have to be redesigned with a material detection circuit, to keep kids from cutting fingers and stabbing eyes - would love to see the actuators made to stop a scissor 5mm from a cornea) ;)

A nice breadboard is good too. One of the engineers at my old job had one made by 3M, he loved it. http://www.digikey.com/en/product-highlight/3/3m/300-series-solderless-breadboards
Yes, 3M knows how to make contacts, but they aren't exactly cheap - I didn't know they made breadboards at all though, I'm more familiar with their ZIF sockets, connectors and bonding products - I might have to check their boards out some day.
 
#11
my dad started building a heathkit (this tells my age) tv whenever i was 12. i was drawn to it. he also purchased a weller trigger gun soldering iron which i soldered with this morning some 50 years later. no i don't work for them. i nave had 12vdc irons for on the road with a long ago car racing team that were invaluable.i have had irons sitting there heating the room up. i have one cold heat saved back as the most stupid idea i ever had.after dad passed i inherited the weller and think it is the best and safest way to go.
 
#12
Hi, we’re a team of engineering undergrads hoping to redesign the soldering iron. Specifically, we’re looking at making it safer and more usable by younger teens and children.

We’re looking for any feedback or advice you might have, especially if you have kids, so if you can spare a few minutes to fill out our survey, that’d be awesome. Or if you have any questions, feel free to shoot us an email at: [email protected]. Thank you for your time and input!

https://docs.google.com/forms/d/14cAsPIbiU_jf09aFBU03nplbYuBtr0JpTPzrWEp4OFw/viewform

also, does anyone know why there is so much metal exposed towards the tip?
My son, then aged about 6yrs, got hold of my soldering iron with his finger and thumb - left a nice brown dent in both! They (kids) seem to be naturally drawn to anything that causes potential harm!

I guess the answer would be to try and debelope 'cold' solder, a kind of glue perhaps!?
 
#13
My son, then aged about 6yrs, got hold of my soldering iron with his finger and thumb - left a nice brown dent in both! They (kids) seem to be naturally drawn to anything that causes potential harm!

I guess the answer would be to try and debelope 'cold' solder, a kind of glue perhaps!?
Or... Behave like a responsible parent: Tell him when something is dangerous, Show him what damage it can do and tell him never to touch it - Follow up with placing it where he can't reach it and never leave such stuff unattended.

I assume that you grew up in a home with sharp kitchen knives and other potentially very harmful gizmos and yet you survived and I don't think you would suggest that all tools were made so blunt that they would not be useful(?) Same thing with lots of other tools, mains electricity or even a piece of string!

What doesn't kill them or render them with severe life long damage makes them, if not stronger, then at least wiser :)

The consequence of over-protecting a child is that they grow into weaker adults.