Induction Soldering Coil with Magnetic Field Concentrator
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current induction soldering methods for photovoltaic systems are inefficient in heating solder material, leading to longer soldering times and higher power consumption due to non-targeted magnetic field distribution.
Innovation Solution
The use of an induction coil with a magnetic field concentrator, such as a circular cylindrical core component, to focus the magnetic field within the coil's eye, enhancing inductive heating efficiency by concentrating the magnetic flux at the solder location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional induction coil soldering is used, then soldering can be performed, but heating efficiency is low and power consumption is high
Solution Approach 1:
The magnetic field concentrator creates a localized region of high magnetic flux density specifically at the solder joint area. The concentrator structure (with its passage and annular shoulder) concentrates the magnetic field lines through the solder material, creating a focused heating zone rather than diffuse heating across the entire interconnect assembly. This local concentration of magnetic energy improves heating efficiency while reducing overall power consumption.
Solution Approach 2:
The magnetic field concentrator acts as an intermediary component between the induction coil and the solder material. It receives the magnetic field from the coil and redirects/concentrates it through the solder joint area. The concentrator structure (comprising the core component and annular shoulder) serves as a magnetic flux guide that enhances the coupling between the induction field and the solder material, improving energy transfer efficiency.
2Productivity
If conventional induction coil soldering is used, then soldering can be performed, but soldering time is prolonged
Solution Approach 1:
By concentrating the magnetic field specifically at the solder joint location, the heating is focused precisely where needed rather than distributing energy across a larger area. This localized heating approach rapidly raises the temperature of the solder material to its melting point, significantly reducing the time required to complete the soldering operation and thereby increasing production throughput.
Solution Approach 2:
The induction coil operates with alternating current that generates a time-varying magnetic field. The magnetic field concentrator structure enhances this periodic magnetic flux through the solder material, creating efficient cyclic heating that rapidly brings the solder to melting temperature. The periodic nature of induction heating combined with the concentrator geometry accelerates the heating rate and reduces cycle time.
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 configuration reduces soldering time by 20% and power consumption by 60% compared to conventional methods, allowing for faster throughput and lower energy usage while ensuring effective soldering.
Implementation Method 1
an induction coil is positioned proximate a contact that is to be soldered to the interconnect. A magnetic field is then generated by the coil due to electrical current passing through the coil, the coil being positioned such that solder material located between the interconnect and the electrical contact melts because of inductive heating of the interconnect and the solder material by the magnetic field
Implementation Method 2
A magnetic field is then generated by the coil due to electrical current passing through the coil, the coil being positioned such that solder material located between the interconnect and the electrical contact melts because of inductive heating
Implementation Method 3
The use of an induction coil with a magnetic field concentrator, such as a circular cylindrical core component, to focus the magnetic field within the coil's eye, enhancing inductive heating efficiency by concentrating the magnetic flux at the solder location
Data Source
AI summary
A method comprises positioning a pair of photovoltaic wafers in a side-by-side arrangement. An interconnect is placed on the pair of wafers such that the interconnect overlaps both wafers of the pair, solder material being provided between the interconnect and the respective wafers. A solder head is then located adjacent the interconnect, and the coil is energized to effect inductive heating of the solder material. The solder head comprises an induction coil shaped to define an eye, and a magnetic field concentrator located at least partially in the eye of the coil. The magnetic field concentrator defines a passage extending axially through the eye of the coil, and may be of a material with a high magnetic permeability.