3D Circuit Terminals on Laser-Engraved Base for Spring Plate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional manufacturing processes for integrating terminals with spring plates in micro lens sets are complex, labor-intensive, and costly, making them unsuitable for automatic production.
Innovation Solution
The use of laser engraving or etching to form 3D circuit terminals on a base, followed by electroplating to create bulged planes and extending ends, which are then soldered or welded to a spring plate for electrical connection, allowing for automatic integration and reduced labor and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional stamping, bending and cutting processes are used to manufacture terminals, then terminals can be produced, but the manufacturing process becomes complex and labor-intensive
Solution Approach 1:
The patent combines multiple manufacturing steps (stampings, bendings, cuttings) into a single laser engraving process that directly creates the terminal structure on the base. This merging of operations simplifies the manufacturing process by eliminating the need for separate terminal manufacturing and assembly steps.
Solution Approach 2:
The patent replaces conventional mechanical stamping, bending and cutting processes with a laser-based engraving process. This substitution eliminates the need for complex mechanical tooling and manual operations, reducing manufacturing complexity while maintaining terminal production capability.
2Reliability
If manual positioning and soldering of terminals are performed, then electrical connection is achieved, but labor cost and production time increase
Solution Approach 1:
The patent performs preliminary actions by directly forming the terminal structure and its electrical connection paths on the base during the laser engraving process. This preliminary creation of the terminal and its wiring areas eliminates the need for subsequent manual positioning and soldering operations, thereby improving productivity while maintaining connection reliability.
Solution Approach 2:
The patent merges the terminal formation process with the base manufacturing process by integrating laser engraving of wiring areas directly into the base structure. This combination eliminates separate terminal assembly operations, reducing labor requirements and production time while ensuring reliable electrical connections through the integrated design.
3Ease of manufacture
If conventional terminal mounting processes are used, then terminals can be connected to the spring plate, but the process cannot be automated
Solution Approach 1:
The patent replaces complex mechanical terminal mounting processes with a laser-based system that can be integrated into automated production lines. The laser engraving process directly creates terminals and wiring areas on the base, enabling automatic production without manual intervention for terminal positioning or soldering.
Solution Approach 2:
The patent utilizes parameter changes in the laser process (such as power, speed, and focus) to control the formation of terminals and wiring areas with precise dimensional control. This level of control enables automation by allowing the process to be programmed and repeated consistently without manual adjustment for each terminal.
4Manufacturing precision
If multiple separate manufacturing steps are used for terminals, then detailed control is possible, but production time and cost increase
Solution Approach 1:
The patent performs all terminal formation actions (creating wiring areas, forming terminal structures) as preliminary steps during the initial laser engraving process on the base. This eliminates subsequent processing steps and reduces production cycle time while maintaining precision through controlled laser parameters and programmed patterns.
Solution Approach 2:
The patent achieves precise terminal dimensional control by carefully controlling laser parameters (power, speed, pulse duration) during the engraving process. This allows single-step formation of precisely dimensional terminals without requiring multiple sequential operations, thereby reducing production time while maintaining manufacturing 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 method significantly reduces the time and labor required for manufacturing, enabling automatic production and eliminating the need for conventional terminal mounting and flexible circuit boards, thereby lowering production costs.
Implementation Method 1
a laser head 9 for performing the laser engraving and/or etching process
Implementation Method 2
a 3D electroplating process is also applied to micro lens set 10 so as to form at least one terminal 3
Implementation Method 3
the terminal/terminals and a spring plate fixed on the top surface of the base are electrically connected
Implementation Method 4
Through soldering or welding process, the terminal/terminals and a spring plate fixed on the top surface of the base are electrically connected
Data Source
AI summary
An apparatus having a spring plate connecting with 3D circuit terminals comprises a base having a top surface and a thickness surface. At least one bulged plane is formed on a predetermined location of the top surface. A side surface of the bulged plane is declined from inside to outside. At least one extending end is formed on the thickness surface of the base, by corresponding to and extending toward a direction opposite to the bulged plane. A declined surface is formed on an outer side of the extending end, by extending and declining from top to bottom and also from inside to outside. At least one metal layer is formed on the bulged plane and the declined surface by means of 3D electroplating in order to form a circuit connecting the terminals and the spring plate.