Galvanic Coating Removal via Laser Ablation for Electrical Connectors
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Solution Overview
Problem
Existing methods for producing electrical connection parts are complex and costly, particularly due to the need for precise masking and adhesive tape application, which complicates the electroplating process and makes automated production inefficient.
Innovation Solution
A method involving electroplating an entire electrical conductor surface and using a beam source, such as a laser, to remove the galvanic coating selectively in the contact area, eliminating the need for masking and ensuring a homogeneous layer thickness while allowing for precise control over the exposed area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If masking with adhesive tape is used to protect specific areas during electroplating, then the seam and joint areas are protected from corrosion, but the production process becomes complex and costly
Solution Approach 1:
The entire conductor surface is electroplated before any exposure or masking operations. This preliminary complete coating ensures that the seam and joint areas are protected from the outset, eliminating the need for complex masking during plating while maintaining corrosion protection reliability
Solution Approach 2:
The adhesive tape masking step is completely removed from the process. Instead of applying tape to protect specific areas, the invention extracts the masking operation entirely and achieves selective exposure through direct removal methods after complete electroplating, thereby simplifying the production process while maintaining protection
2Reliability
If adhesive tape masking is applied to protect the seam area, then corrosion protection is achieved, but adhesive residues and tape remnants contaminate the contact area
Solution Approach 1:
The adhesive tape is completely extracted from the process. The invention replaces tape-based masking with direct beam exposure methods that remove coating without leaving adhesive residues or tape remnants, eliminating contamination of the contact area while maintaining corrosion protection through selective coating removal
Solution Approach 2:
The mechanical adhesive tape system is replaced with a beam-based removal system. Instead of using adhesive forces to protect areas during plating, the invention uses directed beam energy to selectively remove coating after complete electroplating, achieving protection without contamination
3Ease of manufacture
If complete electroplating is performed without masking, then the process is simplified, but the seam area becomes exposed to corrosion
Solution Approach 1:
Complete electroplating is performed as a preliminary action on the entire conductor surface before any selective exposure. This ensures that the seam and joint areas receive full corrosion protection initially, and the simplified process is maintained while reliability is preserved through the subsequent selective removal step
Solution Approach 2:
Instead of protecting specific areas during plating by masking, the invention inverts the approach by completely plating first and then selectively removing coating from areas that need exposure. This reversal maintains both process simplicity and corrosion protection reliability
4Manufacturing precision
If masking is used to expose contact areas after electroplating, then selective exposure is achieved, but the process becomes time-consuming and costly
Solution Approach 1:
The time-consuming masking and tape removal steps are completely extracted from the process. The invention uses direct beam exposure methods that achieve precise contact area exposure without the intermediate masking steps, thereby maintaining manufacturing precision while significantly improving production efficiency
Solution Approach 2:
The mechanical masking system is replaced with a beam-based selective removal system. Instead of applying and removing physical tape masks, the invention uses directed beam energy to precisely expose contact areas directly, eliminating the time-consuming masking steps while maintaining exposure precision
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 approach simplifies the production process, reduces costs, and ensures a reliable, residue-free exposure of the contact area, maintaining the material and electrical properties of the conductor while allowing for flexible geometry adjustments.
Implementation Method 1
the galvanic coating in the contact area is exposed by removing the electroplated coating
Implementation Method 2
the provided electrical conductor is electroplated
Data Source
Figure 1~3
Figure 4~5
Figure 6~8
AI summary
The invention relates to a method for producing an electric connection part in which an electric conductor (2) is provided. The electric conductor is provided such that a first conductor component and a second conductor component are bonded together; the electric conductor (2) is galvanically coated; a contact region (4) of the conductor (2) is exposed by removing the galvanic coating (6) using a radiation source (8); and the electric conductor (2) is provided in the form of a strip, wherein the strip (2) is at least partly separated into strip sections (20) before or after the coating process. The invention is also to provide a method which allows the removal of a galvanic coating (6), which is provided on the connection part (22), in an inexpensive and reliable manner in particular. According to the invention, this is achieved in that the galvanic coating (6) is removed in the contact region (4) using a radiation source (8).