Contact Element Laser Welding on Conductor Plates Without Drilling
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Solution Overview
Problem
Current methods for attaching a contact element to a conductive path on a conductor plate, such as soldering and through-hole technology, are complex and require additional steps like flux removal or drilling, which increase manufacturing complexity.
Innovation Solution
A surface-mounted laser welding method is used to attach the contact element to the conductor plate, where a laser beam is directed onto a flattened end of the contact element to melt and fuse it onto the conductive path, minimizing heat exposure and eliminating the need for holes or flux.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If soldering is used to attach the contact element to the conductive path, then the attachment is achieved, but flux must be removed later which increases manufacturing complexity
Solution Approach 1:
The patent extracts and eliminates the flux removal step from the manufacturing process by using laser welding instead of soldering. The harmful factor (flux) is completely removed from the process, leaving only the essential welding operation.
Solution Approach 2:
The patent replaces the chemical-based soldering process with a physical laser welding process. This substitution eliminates the need for chemical flux and its subsequent removal, simplifying the manufacturing process.
2Ease of manufacture
If through-hole technology is used to attach the contact element, then the attachment is achieved, but drilling of holes is required which increases manufacturing complexity
Solution Approach 1:
The patent extracts and eliminates the drilling operation from the manufacturing process by using surface-mounted laser welding. The complex hole-drilling step is completely removed, leaving only the welding operation.
Solution Approach 2:
Instead of creating holes to pass through the conductor plate and then welding, the patent inverts the approach by welding the contact element directly onto the surface of the conductor plate without any holes, reversing the traditional sequence of operations.
3Strength
If traditional welding methods are used, then the contact element is attached, but thermal stress damages heat-sensitive components on the conductor plate
Solution Approach 1:
The patent applies local quality by concentrating the welding energy precisely at the contact element-conductor plate interface using a focused laser beam. This localized heating minimizes thermal stress on surrounding heat-sensitive components while ensuring strong attachment at the weld point.
Solution Approach 2:
The patent replaces traditional arc welding or resistance welding methods with laser welding, which provides more precise control over heat input and distribution. This substitution reduces unwanted thermal stress on the conductor plate and its components.
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 method simplifies the attachment process by reducing thermal stress on the conductor plate and eliminating the need for drilling or flux, while ensuring a strong and reliable connection without damaging the heat-sensitive components.
Implementation Method 1
welding the contact element to a conductive path of the conductor plate in a surface-mounted manner with a laser beam
Implementation Method 2
a laser beam is directed onto a flattened end of the contact element to melt and fuse it onto the conductive path
Data Source
AI summary
PROBLEM TO BE SOLVED: To provide a laser jointing method that joints two materials while imparting a sufficient strength thereto and minimizing heat influence. SOLUTION: The method overlaps first and second materials (V1, V2) on each other and irradiates the surface of the first material (V1) with a laser light (103) from the side of the first material (V1). When jointing both materials (V1, V2), the method intermittently irradiating an overlapped part of the first and second materials (V1, V2) with the laser light while moving the laser light (103) to form a welding bead (1) on the surface of the first material (V1), wherein the length of the welding bead (1) is formed gradually shorter.