Flat Cable Laser Resin Removal for Solder Bridge
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Solution Overview
Problem
Existing flat cable technologies face challenges in efficiently and reliably connecting conductors between adjacent wires without damaging the insulating resin, particularly when trying to form solder-bridges between specific points along the cable, which is crucial for applications like thermocouples or heat sensors.
Innovation Solution
The flat cable design involves arranging insulated wires with different insulation layers, where the outer second insulation layer is removed using a CO2 laser and the inner first insulation layer is removed using a YAG laser, allowing for precise exposure and soldering of conductors between adjacent wires, enabling secure electrical connections without damaging the resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser irradiation is used to remove insulating resin, then conductor exposure is achieved, but risk of resin damage increases
Solution Approach 1:
The insulating resin is removed in two distinct stages using two different laser types: CO2 laser for bulk resin removal and YAG laser for precise conductor exposure. This segmentation allows each laser to be optimized for its specific function, achieving both efficient resin removal and precise conductor exposure without damaging the resin
Solution Approach 2:
Different laser parameters (wavelength, power, pulse duration) are used for different removal stages. The CO2 laser operates at a wavelength absorbed by the resin for bulk removal, while the YAG laser uses parameters optimized for precise conductor exposure. This parameter optimization minimizes resin damage while achieving precise conductor exposure
2Manufacturing precision
If traditional insulating resin removal methods are used, then conductor exposure is achieved, but operation time increases
Solution Approach 1:
Traditional mechanical or chemical insulating resin removal methods are replaced with laser irradiation. The laser beam directly ablates the resin without mechanical contact or chemical reactions, significantly reducing operation time while maintaining precise conductor exposure
Solution Approach 2:
The laser removal process uses pulsed irradiation with optimized pulse duration and frequency. This periodic action allows controlled resin removal with heat dissipation between pulses, preventing resin damage while maintaining high removal efficiency and reducing total operation time
3Ease of manufacture
If insulating resin is completely removed, then conductor connection is facilitated, but cable insulation integrity deteriorates
Solution Approach 1:
The insulating resin is selectively removed only in the specific soldering portions where conductor connection is needed, while the rest of the cable maintains its insulation integrity. The YAG laser precisely targets the conductor exposure area, creating localized conductor exposure without compromising the overall cable insulation structure
Solution Approach 2:
The insulating resin is extracted only from the specific soldering portions where connection is required, rather than removing it from the entire cable. This selective extraction facilitates conductor connection at connection points while preserving insulation integrity in non-connection areas
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 allows for efficient and reliable formation of solder-bridges between conductors, enhancing the cable's functionality as a thermocouple or heat sensor by ensuring secure electrical connections and reducing operation time compared to traditional methods.
Implementation Method 1
the outer surfaces of the plurality of insulated wires are integrated, wherein the insulating resin of the plurality of insulated wires is removed by laser in a soldering portion
Implementation Method 2
a method of irradiating the polyurethane coating of a polyurethane coated wire with YAG laser to remove it
Implementation Method 3
Two mutually adjoining insulated wires among the plurality of insulated wires are electrically connected to each other by soldering in the soldering portion
Data Source
AI summary
The flat cable is structured such that a plurality of insulated wires with their conductors covered with insulating resin are arranged in parallel and the outer surfaces of the plurality of insulated wires are integrated. The insulating resin between two insulated wires is removed by laser beam in a soldering portion, and, among the plurality of insulated wires, only two mutually adjoining insulated wires are electrically connected to each other by soldering in the soldering portions in which the insulating resin are removed and the conductors are exposed. Such flat cable can positively solder bridge the mutually adjoining conductors.