Ferrite Hold-Down Devices for Precise Induction Soldering
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Solution Overview
Problem
Existing soldering devices for connecting solar cells using the induction principle are complex and expensive, making it difficult to achieve high-quality soldered joints, especially on small surfaces.
Innovation Solution
A soldering device with a heat source using an inductor loop and hold-down devices designed as field concentrators, which amplify and concentrate the magnetic field for precise soldering, allowing for efficient and cost-effective soldering of solar cells, even on small areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional inductor loops without ferrite concentration are used, then the structure is simple and inexpensive, but the magnetic field cannot be concentrated for precise soldering on small surfaces
Solution Approach 1:
The patent applies local quality by making only the hold-down devices ferrite-based field concentrators while keeping the inductor loop structure conventional. This localized application of ferrite material concentrates the magnetic field precisely where needed (at the soldering points) without requiring complex ferrite integration throughout the entire inductor loop, thus achieving precise soldering on small surfaces while maintaining structural simplicity
Solution Approach 2:
The hold-down devices serve as intermediary field concentrators that mediate between the conventional inductor loop and the solar cell conductor tracks. These ferrite hold-down devices concentrate the magnetic field generated by the simple inductor loop into focused zones at the contact points, enabling precise soldering without modifying the basic inductor loop design
2Manufacturing precision
If ferrite field concentrators are integrated into the inductor loop, then magnetic field concentration is achieved for precise soldering, but the device becomes more complex and expensive
Solution Approach 1:
The patent uses inexpensive ferrite hold-down devices as disposable or replaceable components rather than integrating expensive ferrite structures into the permanent inductor loop. These simple ferrite hold-down devices can be easily manufactured and replaced if needed, making the overall system cost-effective while achieving the required soldering precision through magnetic field concentration
3Manufacturing precision
If conventional hold-down devices are used with simple inductor loops, then the device is inexpensive, but high-quality soldered joints cannot be achieved on small surfaces
Solution Approach 1:
The hold-down devices are transformed from simple mechanical pressers into localized magnetic field concentrators by incorporating ferrite material. This local quality enhancement concentrates the magnetic field energy precisely at the soldering points where the conductor contacts the solar cell, enabling high-quality soldered joints on small surfaces while keeping the overall device structure relatively simple
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
The solution enables high-quality, precise soldering of solar cells on small surfaces with reduced complexity and cost, using conventional inductor loops and inexpensive ferrite-based hold-down devices, achieving excellent soldering results.
Implementation Method 1
A high-frequency current from the high-frequency generator generates a high-frequency magnetic field, which induces eddy currents via the inductor loop in the conductor track and in the electrical conductor arranged along the conductor track, which generate the heat required for the soldering process
Implementation Method 2
A high-frequency current from the high-frequency generator generates a high-frequency magnetic field, which induces eddy currents via the inductor loop in the conductor track and in the electrical conductor arranged along the conductor track, which generate the heat required for the soldering process
Implementation Method 3
A high-frequency current from the high-frequency generator generates a high-frequency magnetic field, which induces eddy currents via the inductor loop in the conductor track and in the electrical conductor arranged along the conductor track, which generate the heat required for the soldering process
Implementation Method 4
The hold-down device or devices are designed as field concentrators, which means that the magnetic field can be locally amplified and concentrated in the target area where soldering is to take place
Implementation Method 5
The at least one hold-down device consists at least partially of a ferrite or another material with high magnetic permeability
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
A soldering device for connecting solar cells (9) comprises an inductor loop (2) for generating a high-frequency magnetic field for soldering conductors to the solar cells and clamps (3) penetrating the inductor loop for pressing the conductor (10) onto the conductor tracks of the solar cells (9). A field concentrator element (7) made of ferrite is arranged in each clamp pin (5) of the clamps (3), which allows the magnetic field to be locally strengthened and concentrated.