Induction Soldering Ferrite Core for Vehicle Window Glass
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Solution Overview
Problem
Conventional soldering methods for terminals on vehicle window glass using induction coils face issues such as flux burning, premature solidification of solder, and quality degradation due to exposure to air, leading to thermal stress and potential glass cracking.
Innovation Solution
An apparatus and method utilizing an induction coil and a ferrite core to melt solder directly on the window glass, with the ferrite core pressing the terminal and induction heat being concentrated to prevent unnecessary heating of the glass, ensuring the solder is melted in the target area without exposure to air.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a soldering iron is used to melt solder alloy, then the solder alloy can be melted effectively, but thermal stress is generated in the window glass which may cause the glass to shatter
Solution Approach 1:
The induction coil is positioned to generate electromagnetic induction heat only at the specific location where the solder alloy needs to be melted, rather than heating the entire window glass surface. This localized heating approach melts the solder alloy effectively while avoiding widespread thermal stress that could cause glass shattering.
Solution Approach 2:
The patent replaces the mechanical contact heating method of a soldering iron with an electromagnetic induction heating system. The induction coil generates electromagnetic fields that directly induce current in the solder alloy, converting electrical energy to thermal energy without mechanical contact, thereby eliminating the thermal stress problem associated with conventional soldering irons.
2Object-affected harmful factors
If an induction coil is used to melt pre-attached solder alloy, then the solder alloy can be melted without thermal stress on glass, but the flux burns and the solder may solidify before reaching the target area
Solution Approach 1:
The solder alloy is pre-attached to the terminal in a controlled state before the induction heating process begins. This preliminary positioning ensures that the solder is in the correct location and condition before exposure to induction heat, preventing premature solidification and ensuring proper flux protection during the melting process.
Solution Approach 2:
The induction coil and ferrite core are designed to dynamically adjust the concentration and distribution of induction heat during the soldering process. This dynamic control allows the heat to be concentrated precisely where needed, maintaining solder in a molten state long enough to flow to the target area without premature solidification, while still protecting from excessive thermal stress on the glass.
3Ease of operation
If melted solder is exposed to air during induction heating, then the soldering process can be performed, but the quality of soldering is affected by the external environment
Solution Approach 1:
The induction heating system creates a controlled heating zone where the solder alloy is melted rapidly and contained. The ferrite core and coil configuration concentrates the electromagnetic energy in a specific region, effectively creating a localized environment that protects the molten solder from adverse external environmental factors such as air exposure, while still allowing the process to be performed.
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 maintains high soldering quality by preventing flux burning and premature solidification, reducing energy waste by 30-35%, and minimizing thermal stress on the glass, thereby enhancing the reliability of the soldering process.
Implementation Method 1
a coil unit (20) comprising a coil (21) which generates induction heat
Implementation Method 2
a coil unit (20) comprising a coil (21) which generates induction heat
Implementation Method 3
a ferrite core unit (40) comprising a ferrite core (41) which is configured to be surrounded by the coil unit (20) to receive the induction heat
Data Source
Figure 1~2
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Figure 5
AI summary
The present invention provides an apparatus for soldering a terminal to which a solder alloy is attached on window glass for a vehicle, the apparatus comprising: a terminal to which the solder alloy is attached; a coil unit comprising a coil which generates induction heat; a gripper which grips and releases the terminal and is configured to be movable upward and downward relative to the coil unit in a state of gripping the terminal; and a ferrite core unit comprising a ferrite core which is configured to be surrounded by the coil unit to receive the induction heat, and is configured to be movable upward and downward relative to the coil unit, wherein the solder alloy attached to the terminal, in a state of being in contact with the window glass, is melted by the induction heat from the coil unit and the ferrite core unit such that the terminal is attached to the window glass.