Laser Reflow Melting for Terminal Tin Coating
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Solution Overview
Problem
Current reflow tin melting processes, such as electric furnace/infrared baking and inductive melting, face inefficiencies, high energy consumption, and poor stability due to thermal radiation heating and lack of localized heat control, leading to difficulties in assembly, damage to tin coatings, and increased risk of tin whisker growth causing short circuits.
Innovation Solution
A reflow melting system utilizing a laser head to emit laser light for precise heating and melting of metal coatings on terminals, with a remote control terminal for adjusting working parameters to optimize melting, and image sensors for real-time monitoring and correction, enabling precise control and high-quality recrystallization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If electric furnace/infrared baking is used for reflow melting, then melting can be achieved, but energy consumption is high and heating efficiency is low
Solution Approach 1:
The patent replaces the traditional electric furnace/infrared baking system with a laser heating system. The laser directly irradiates the tin coating to induce localized melting, eliminating the need for large-scale thermal radiation heating. This substitution of heating mechanism dramatically improves energy efficiency by concentrating energy only where needed, rather than heating the entire workpiece and surrounding environment.
Solution Approach 2:
The laser heating system applies energy locally to specific areas of the tin coating that require melting, rather than uniformly heating the entire workpiece. This localized heating approach reduces energy consumption by avoiding unnecessary heating of adjacent areas, while still achieving the required melting effect for improving contact resistance and reducing friction.
2Productivity
If inductive melting is used, then heating efficiency is high, but stability of melting process is poor due to sensitivity to work piece position
Solution Approach 1:
The patent replaces the inductive heating system with a laser heating system. The laser provides direct optical energy transfer to the tin coating, achieving high heating efficiency similar to inductive melting. However, unlike inductive heating which is highly sensitive to the position and orientation of the workpiece relative to the induction coil, the laser system maintains stable heating effectiveness regardless of minor position variations, thereby improving process reliability.
3Manufacturing precision
If thermal radiation baking is used, then melting can be achieved, but quality stability control is difficult and equipment size is large
Solution Approach 1:
The patent replaces the large-scale thermal radiation baking equipment with a compact laser heating system. The laser can be precisely controlled to deliver consistent energy levels to the tin coating, enabling stable quality control. The compact nature of laser equipment significantly reduces the space requirement compared to large electric furnaces or infrared baking chambers, while achieving superior repeatability and control of the melting process.
4Reliability
If conventional reflow processing is used, then tin coating can be melted and recrystallized, but insertion force increases and damage to tin coating occurs
Solution Approach 1:
The laser heating system selectively melts only the tin coating layer without excessively heating the underlying base metal or intermediate coating layers. This localized and controlled melting approach prevents overheating damage to the tin coating, maintaining its integrity while achieving the desired recrystallization. The result is improved contact resistance and reduced friction without the coating damage that occurs in conventional reflow processing.
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
The laser-based system achieves efficient, precise, and stable reflow melting with reduced energy consumption, improved wear resistance, lower contact resistance, and minimized oxidation, enhancing the quality and durability of the tin coating.
Implementation Method 1
a laser head for emitting a laser light onto the metal coating on the terminal to heat and melt the metal coating
Implementation Method 2
emitting a laser light onto the metal coating on the terminal to heat and melt the metal coating
Data Source
AI summary
A reflow melting system for reflow melting a metal coating on an electrical contact area of a terminal includes a laser head for emitting a laser light onto the metal coating on the terminal to heat and melt the metal coating. A remote control terminal is provided in communication with the laser head for adjusting at least one working parameter of the laser head for optimizing the melting effect of the metal coating.