Laser Soldering Head Alignment for E-Cigarette Heating Circuits

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Solution Overview

Problem

The existing laser soldering methods for electronic cigarettes face challenges in achieving high-quality solder connections due to the non-perpendicular angle of the laser beam, which complicates control and can damage the coil, especially with the reduced transverse dimensions of the coil.

Innovation Solution

A movable laser soldering head that generates two distinct pulses, allowing the laser beams to be perpendicular to the surfaces, with the terminals interposed between the beam and the coil to ensure precise soldering without damaging the coil.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a fixed laser soldering head with beam deflection mirrors is used to solder both terminals, then the device can perform soldering at both terminals, but the laser beam makes a non-negligible angle with the perpendicular to the surface, making it difficult to control and negatively affecting solder quality

Engineering Contradiction:

Improveability to solder both terminalsVSAvoidsolder quality

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent divides the soldering process into two separate operations: a first laser soldering head solderes the first terminal, and a second laser soldering head solderes the second terminal. Each head is positioned to deliver the laser beam perpendicularly to its respective terminal surface, eliminating the angular deviation problem that would occur with a single fixed head using mirrors.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a movable support structure that carries both laser soldering heads and can be positioned to align each head perpendicular to its target terminal. This intermediary mechanism enables precise angular positioning without requiring complex mirror deflection systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If a single fixed laser soldering head is used with beam deflection, then the device structure is simplified, but the coil with reduced transverse dimensions is likely to be damaged if struck directly by the laser beam

Engineering Contradiction:

Improvesoldering device structureVSAvoidcoil damage risk

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The patent employs separate laser soldering heads for each terminal, with each head independently positioned to target only its designated terminal. This segmentation ensures that the laser beam is precisely directed at the terminal surfaces and does not stray to damage the nearby coil, even though the coil has reduced transverse dimensions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each laser soldering head is specifically positioned and configured to deliver the laser beam only to its assigned terminal location. This localized approach ensures that the high-energy laser beam is concentrated exactly where needed (at the terminal-solder interface) and does not affect adjacent sensitive components like the coil.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If a movable laser soldering head is used to maintain perpendicular beam alignment, then soldering quality is maximized, but the device complexity increases

Engineering Contradiction:

Improvelaser beam perpendicularityVSAvoidmovable support structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The support structure is designed to be movable, allowing the laser soldering heads to be dynamically repositioned between soldering operations on different terminals. This dynamic capability enables maintaining perpendicular beam alignment while adapting to different soldering locations.

Inventive Principle:

Principle #15Dynamics

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 ensures high-quality solder connections by maintaining the laser beams perpendicular to the surfaces, preventing coil damage and enabling efficient, high-speed production in electronic cigarette assembly.

Implementation Method 1

an electric circuit connected to an energy source, for example a battery, is configured to produce heat by the Joule effect

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

laser soldering of the coil to the terminals in a process for making an electronic cigarette

Methodology Applied

Scientific EffectLaser heating: Laser

Data Source

PatentUS10994353B2Method and device for laser soldering an electric circuit of a heating portion of an electronic cigarette

Publication Date: 2021.05.04 GD SPA

AI summary

A laser soldering device for laser soldering an electric circuit of a heating portion of an electronic cigarette, the soldering device including a head having an emitting area where a laser beam is emitted and a feeding device to feed a heating portion of an electronic cigarette along a feed path, where the heating portion faces the head at the emitting area. A movement device is operatively connected to the head to move the head between first and second points of the electric circuit such that the laser beam is perpendicular to the respective surface to be soldered at the first and second points to form first and second connections, respectively. The head generates two distinct pulses of the laser beam at the first and second points.