Laser Welding Conductive Components Using Geometric Reflection
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Solution Overview
Problem
Existing methods for connecting electrically conductive components using a laser beam require complex and precise mask devices to protect the encapsulation from laser radiation, limiting the number of possible contact points and necessitating high-precision positioning.
Innovation Solution
The first component is raised in the connection zone to ensure that the laser beam does not hit the encapsulation, with a geometric configuration that prevents reflection or scattering from damaging the overmolding, and a recess design that allows the second component to be in contact without a protective mask.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a protective mask is used to prevent laser radiation from damaging the encapsulation, then the encapsulation is protected from thermal stress, but the device complexity increases and the number of possible contact points is limited
Solution Approach 1:
The patent removes the protective mask entirely by extracting the harmful reflection path through geometric design. The first component is shaped to reflect laser radiation away from the encapsulation, eliminating the need for a separate protective element and simplifying the overall device structure.
Solution Approach 2:
The solution moves from a two-dimensional protective mask overlay to a three-dimensional geometric configuration of the first component itself. By designing the component's shape in 3D space, the reflection path is controlled spatially, allowing protection without additional components.
2Object-affected harmful factors
If a protective mask is used to prevent laser radiation damage, then the encapsulation is protected, but the number of possible electrically conductive contact points is limited
Solution Approach 1:
By removing the protective mask entirely and using geometric reflection instead, the patent eliminates the spatial constraint that limited contact points. The first component can now have multiple contact points with the second component without requiring mask openings or complex positioning mechanisms.
3Object-affected harmful factors
If a protective mask is used to prevent laser radiation damage, then the encapsulation is protected, but high-precision positioning is required
Solution Approach 1:
The patent eliminates the positioning problem by removing the mask entirely. The geometric reflection is inherent to the first component's shape, requiring no separate positioning of protective elements during assembly or operation.
Solution Approach 2:
The first component serves dual functions: it provides the electrical connection and simultaneously protects the encapsulation through its own geometric shape. The component's structure automatically controls the laser reflection path without requiring external protective elements or complex positioning systems.
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 eliminates the need for a protective mask, increasing the number of possible contact points and simplifying the positioning process while preventing thermal stress to the encapsulation material.
Implementation Method 1
connecting two electrically conductive components by means of a laser beam
Implementation Method 2
By melting the second component, which is in contact with the first component, a non-positive or positive connection is formed
Implementation Method 3
a geometric configuration that prevents reflection or scattering from damaging the overmolding
Implementation Method 4
prevents the material of the overmolding on the side facing the laser beam from being damaged as a result of scattering or partial reflection of the laser beam
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a method for connecting two electrically conductive components (1; 1a, 2) by means of a laser beam (10), wherein the first component (1; 1a) facing the side of the laser beam (10) is provided in certain areas with an overmolding (12) made of plastic and has a recess (13, 14) free of the overmolding (12) at least on one side in the area of a connection zone (5) of the two components (1; 1a, 2), and wherein the second component (2) facing away from the laser beam (10) is in contact with the first component (1; 1a) at least in certain areas in the area of the connection zone (5). According to the invention, in a first embodiment of the invention, a plastic permeable to the laser beam (10) is used as the plastic for the overmolding (12) of the first component (1; 1 a), and the recess (13) is formed at least on the side of the first component (1; 1 a) facing away from the laser beam (10).