Laser-Fastened Contact Element for Ceramic Base Reliability
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Solution Overview
Problem
Existing methods for fastening contact elements in electrical components, such as soldering and welding, face reliability issues due to temperature limitations and high costs, and are prone to damage and process complexity, especially in high-temperature applications and humid environments.
Innovation Solution
A method involving the use of a laser beam to partially melt and solidify a contact element's protruding region, forming a connecting material that securely fastens the contact element to a ceramic base body without directly heating the base body, thus preventing damage and simplifying the process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If soldering is used to fasten connecting wires on metallization, then electrical contact is achieved, but the usage temperature is limited by the melting temperature of the solder and reliability decreases under frequent alternating temperature stresses
Solution Approach 1:
The patent changes the physical state and material properties by melting the contact element itself to form a bonding material, rather than using a separate solder material with limited temperature resistance. This allows the bonding process to occur at temperatures suitable for high-temperature applications while maintaining reliability.
Solution Approach 2:
The patent uses the contact element's own material (which would otherwise be wasted) as the bonding material. By melting a portion of the contact element to create the bonding substance, the invention eliminates the need for separate solder materials and achieves reliable high-temperature connections.
2Temperature
If gold metallization with sintering paste is used for higher usage temperatures, then temperature resistance is improved, but production costs increase due to gold material and complex process control
Solution Approach 1:
The patent replaces expensive gold metallization and sintering paste with the contact element's own material. By melting a portion of the contact element to form the bonding material, the invention eliminates costly materials and complex multi-step processes (paste application, drying, burning in) while achieving high-temperature resistance.
Solution Approach 2:
The patent combines the contact element and bonding material into a single integrated solution. Instead of using separate gold metallization and sintering paste, the contact element itself serves as both the electrical contact and the bonding material, simplifying the manufacturing process and reducing costs.
3Strength
If welding is used to fasten connecting wires, then fastening strength is improved, but the risk of destruction of the base body and metallization increases
Solution Approach 1:
The patent applies localized melting only to the contact element's protruding region, not the entire contact area or the base body. This localized approach creates strong bonding at the contact point while avoiding thermal damage to the base body and metallization that would occur with conventional welding.
Solution Approach 2:
The patent uses the molten material from the contact element itself as an intermediary bonding substance. This molten material acts as a mediator between the contact element and the base body, creating a strong bond without requiring the high temperatures and direct heat application that cause damage in conventional welding.
4Ease of manufacture
If conventional fastening methods are used, then process simplicity is maintained, but manufacturing precision and reliability decrease due to material migration in humid environments
Solution Approach 1:
The patent changes the material state from solid to molten and back to solid, creating a bonding structure that is resistant to material migration. The solidified molten material forms a stable bond that does not migrate in humid environments, while the process remains simple as it uses the contact element's own material without requiring additional bonding agents.
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 provides a reliable, cost-effective, and damage-free fastening solution that maintains component stability and reliability across varying temperatures, while avoiding thermal strain on the base body and reducing the risk of mechanical damage.
Implementation Method 1
the contact element is partially melted by the laser beam
Implementation Method 2
a region of the contact element is struck by the laser beam and melted
Data Source
AI summary
An electrical component includes a base body having a contact surface on which a contact element is fastened by a solidified molten material, wherein the material is formed by a molten region of the contact element.