Laser Welded Connector Assembly With Transmitting And Absorbing Materials

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Solution Overview

Problem

Existing connector assemblies face challenges in achieving a compact and watertight structure while ensuring reliable electrical connections and preventing fluid ingress, particularly when subjected to laser welding processes.

Innovation Solution

The connector assembly incorporates a first connector with a transmitting material and a second connector with an absorbing material, both connected through laser welding, where the transmitting material allows the laser to pass through and the absorbing material absorbs it, ensuring a secure and compact bond without additional sealing requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional connector assembly methods are used, then additional sealing components are required, but this increases device complexity and manufacturing steps

Engineering Contradiction:

Improvewatertight connectionVSAvoidsealing structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces mechanical sealing systems with laser welding technology. Instead of using separate sealing components and mechanical assembly steps, the invention uses laser-induced welding to directly bond the connector body and terminal, achieving watertight connections through material fusion rather than mechanical sealing. This substitution eliminates the need for additional sealing structures while maintaining connection reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the material parameters of the connector components by incorporating laser-absorbing materials and transmitting materials with specific optical properties. These parameter changes enable the materials to respond differently to laser irradiation, facilitating precise welding control and eliminating the need for separate sealing components. The modified material parameters allow for direct laser welding that achieves both structural bonding and sealing functionality.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If laser welding is applied to connector assembly, then manufacturing precision is improved, but additional sealing measures are needed to prevent fluid ingress

Engineering Contradiction:

Improvewelding precisionVSAvoidfluid ingress

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Volume of moving object

If compact connector design is implemented, then space efficiency is improved, but reliable electrical connection and fluid sealing become more difficult to achieve

Engineering Contradiction:

Improveconnector sizeVSAvoidelectrical connection reliability

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent merges multiple functions into a single integrated connector design. The connector body and terminal are directly bonded through laser welding, combining structural support, electrical connection, and fluid sealing functions into one unified assembly. This merging eliminates the need for separate sealing components and mechanical fasteners, achieving compact dimensions while maintaining reliable electrical and environmental sealing performance.

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 configuration enables a compact and durable connector assembly with enhanced reliability in electrical connections and resistance to fluid ingress, achieved through the precise laser welding process that eliminates the need for additional sealing between the connectors.

Implementation Method 1

the transmitting material allows the laser to pass therethrough

Methodology Applied

Scientific EffectLaser transmission: Laser

Implementation Method 2

the other disposed on a relatively inner side has an absorbing material that absorbs the laser

Methodology Applied

Scientific EffectLaser absorption: Absorption (EM radiation)

Implementation Method 3

The first connecting portion and the second connecting portion are connected to each other through laser welding

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Data Source

PatentUS11189954B2Connector assembly and method of manufacturing the same

Publication Date: 2021.11.30 TYCO ELECTRONICS AMP KOREA

AI summary

A connector assembly includes a first connector having a first connector body and a first connecting portion protruding from the first connector body, a second connector having a second connector body and a second connecting portion protruding from the second connector body, the second connecting portion overlapping the first connecting portion in a direction perpendicular to a central axis of the second connector, and a terminal fastening lance protruding from the first connector body and extending on an inner side of the second connector body. Of the first connecting portion and the second connecting portion, one disposed on a relatively outer side has a transmitting material that allows a laser to pass therethrough and the other disposed on a relatively inner side has an absorbing material that absorbs the laser. The first connecting portion and the second connecting portion are connected to each other through laser welding.