Laser Welding Stranded Wire to Metal Plate Using Localized Heating
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Solution Overview
Problem
Existing laser welding techniques require excessive thermal energy to melt both conductive metal plates and wires, leading to inefficiencies and potential sputtering issues, especially when materials have different melting points.
Innovation Solution
Applying a laser beam to the conductive metal plate with a higher melting point than the wire, causing it to melt first and transfer heat to ensure the wire is melted without excess energy, while maintaining a wide shape and larger cross-sectional area to ensure effective heat transfer and prevent sputtering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the laser beam is applied to both the wire and the conductive metal plate simultaneously to ensure both are melted, then the welding reliability is improved, but the total thermal energy required increases excessively
Solution Approach 1:
The patent applies local quality by directing the laser beam to irradiate only the conductive metal plate (the part with higher melting point) rather than both components simultaneously. The conductive metal plate's larger cross-sectional area and higher melting point make it the appropriate target for localized laser heating, which then transfers heat to the wire through thermal conduction during the welding process.
Solution Approach 2:
The patent utilizes parameter changes by exploiting the difference in melting points between the wire and the conductive metal plate. By selecting materials with different melting point parameters and using the conductive metal plate's higher melting point as a thermal reservoir, the system achieves reliable welding with reduced total energy input.
2Manufacturing precision
If the total thermal energy is increased to ensure both wire and conductive metal plate are melted without fail, then the welding completeness is improved, but sputtering occurs and productivity decreases
Solution Approach 1:
The patent applies local quality by concentrating the laser beam energy on the conductive metal plate's surface, which has higher melting point and larger cross-sectional area. This localized heating approach ensures complete melting of both components while minimizing excess energy that would cause sputtering and reduce productivity.
3Use of energy by moving object
If the laser beam is applied to the conductive metal plate with higher melting point, then the total thermal energy is reduced, but it must be ensured that the wire is still melted completely
Solution Approach 1:
The patent applies local quality by selecting the conductive metal plate as the laser irradiation target based on its higher melting point and larger cross-sectional area. This localized approach ensures that the plate absorbs sufficient energy to melt and transfer heat to the wire, guaranteeing complete wire melting while reducing total energy requirements.
Solution Approach 2:
The conductive metal plate acts as an intermediary in the welding process. It absorbs the laser beam energy first, melts, and then transfers the thermal energy to the wire through thermal conduction and direct contact during the welding process, ensuring complete wire melting without requiring direct laser irradiation of the wire.
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 reduces the total thermal energy needed for welding, improves connection quality, and enhances productivity by minimizing sputtering and ensuring reliable bonding.
Implementation Method 1
applying a laser beam to the conductive metal plate with a higher melting point than the wire, causing it to melt first
Implementation Method 2
Applying a laser beam to the conductive metal plate... causing it to melt first and transfer heat
Implementation Method 3
transfer heat to ensure the wire is melted without excess energy
Implementation Method 4
causing it to melt first
Data Source
AI summary
A laser welding structure that is formed by joining a stranded wire (wire) of a signal line and a welding portion (conductive metal plate) by locally applying a laser beam and thereby melting and solidifying the stranded wire of the signal line and the welding portion has the following features. That is, the melting point of the stranded wire of the signal line and the melting point of the welding portion are different. The laser welding structure is obtained by applying a laser beam to one of the stranded wire of the signal line and the welding portion that has a higher melting point, i.e., to the welding portion having a higher melting point.