Laser-Textured Conductor Assembly for Impermeable Plastic Overmolding

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Solution Overview

Problem

Existing methods for manufacturing electrical or electronic component parts with conductor elements and plastic structures fail to achieve robust, reliable, and durable impermeability to gases and liquids, especially under extreme loads, while also being cost-effective and efficient in process time.

Innovation Solution

The method involves creating groove-like depressions on the peripheral faces of conductor element blanks using laser light sources before overmolding with plastic, ensuring a robust and impermeable bond by overlapping grooves on adjacent faces, which reduces manufacturing costs and time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional bonding methods are used between conductor element and plastic structure, then manufacturing is simple, but the bond lacks robustness, reliability and durable impermeability

Engineering Contradiction:

Improvebond robustness and impermeabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The groove-like depressions are created on the conductor element surface before the overmolding process. This preliminary surface preparation enables the plastic structure to mechanically interlock with the conductor element, forming a robust and impermeable bond that withstands extreme loads, while maintaining manufacturing efficiency through a single integrated process step

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The groove-like depressions create localized surface features with specific geometric properties (depth, width, spacing) that enhance adhesion. These localized structural modifications provide superior bonding characteristics at the interface between conductor element and plastic structure without requiring complex manufacturing processes throughout the entire component

Inventive Principle:

Principle #3Local quality

2Strength

If complex surface treatment methods are used to improve adhesion, then bond strength increases, but manufacturing time and costs increase

Engineering Contradiction:

Improveadhesion strengthVSAvoidmanufacturing cycle time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The invention replaces complex mechanical surface treatment processes (such as multi-step machining, blasting, or coating operations) with a streamlined laser-based groove formation process. This substitution achieves superior adhesion strength through precise groove geometry while significantly reducing manufacturing cycle time and operational complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The groove-like depressions are characterized by specific geometric parameters (depth of 5-50 μm, width of 5-40 μm, spacing of 10-100 μm) that are optimized to maximize adhesion strength. By controlling these parameters within defined ranges, the process achieves high bond strength while maintaining efficient manufacturing throughput

Inventive Principle:

Principle #35Parameter changes

3Reliability

If thorough surface structuring is applied to all peripheral faces, then impermeability improves, but process complexity and time increase

Engineering Contradiction:

Improveimpermeability to gases and liquidsVSAvoidsurface treatment system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The laser processing system integrates the formation of groove-like depressions across multiple adjacent peripheral faces into a single continuous operation. The grooves on adjoining faces are created in an uninterrupted manner, ensuring consistent impermeability throughout the entire conductor element surface while simplifying the manufacturing system architecture and reducing process time

Inventive Principle:

Principle #5Merging (Combining)

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 results in a component part with a strong, reliable, and durable bond between the conductor element and plastic structure, meeting high requirements for robustness and impermeability, even under extreme conditions, while minimizing production costs and time.

Implementation Method 1

making, by means of one or two laser light sources, groove-like depressions on all peripheral faces of the conductor element blanks

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS11752674B2Electrical or electronic assembly and method for producing an electrical or electronic component

Publication Date: 2023.09.12 KOLEKTOR GRP D O O

AI summary

A method is provided for the production of an electrical or electronic component having a conductor element with two contact points and a plastic structure injection-molded thereon. A strip-type metal substrate, having multiple conductor element blanks and a carrier structure, is provided. Grooved depressions are produced on all peripheral surfaces of the blanks on a texturing section with one or two laser light sources. With a single laser light source the grooved depressions are produced on at least two primary peripheral surfaces which adjoin one another and form a common edge such that a multiplicity of the grooved depressions extends without interruption continuously into the primary peripheral surfaces. A conductor element blank is separated from the carrier structure. The resulting conductor element is encapsulated with plastic by injection molding on all peripheral surfaces within a section to be encapsulated. The plastic structure thereby formed extends into the grooved depressions.