Integrated Miniature Welding Plate for Electronic Component Connection
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Solution Overview
Problem
Conventional welding methods fail to effectively connect miniature electronic components due to small welded dots and scattered welding wires, leading to loose connections and reduced efficiency in miniaturized electronic devices.
Innovation Solution
An integrated miniature welding plate structure with pads and welding holes, where welding wires are connected to pads through conductive layers, ensuring electrical conductivity and improved connection strength, featuring a manufacturing process involving punching, electroplating, gluing, and cutting to create a stable and efficient welding solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding methods are used to directly weld welding wires with miniature welded dots, then welding can be performed, but the welded dots easily fall off and welding wires scatter and separate
Solution Approach 1:
The patent introduces a welding plate as an intermediary component between the welding wire and the miniature electronic component. The welding plate includes a base plate with through-holes containing conductive metal conductors that extend through the plate. The welding wire is first welded to the conductive layer on the welding plate, then the assembly is welded to the electronic component pad. This intermediary structure provides a larger welding area and better mechanical support, preventing welded dot detachment and wire scattering while maintaining electrical conductivity.
2Productivity
If welding wires are directly welded with miniature welded dots, then connection can be established, but welding efficiency is low and wire arrangement is difficult to control
Solution Approach 1:
The patent merges multiple welding operations into a single integrated welding plate structure. Multiple conductors are arranged in through-holes of the base plate, allowing multiple welding wires to be welded to the plate simultaneously or in sequence before attaching to the component. The welding plate integrates mechanical support, electrical conduction, and wire positioning functions into one component, simplifying the overall welding process and improving efficiency despite the added component.
3Volume of moving object
If welded dots are made smaller for miniature electronic components, then component size is reduced, but welding precision and connection reliability deteriorate
Solution Approach 1:
The patent transitions from two-dimensional dot welding to three-dimensional conductor arrangement. The conductive metal conductors extend through the base plate in the vertical dimension, providing welding surfaces on both the top and bottom faces of the plate. This vertical dimension allows welding wires to be attached to the conductive layer on the welding plate with sufficient contact area, even when the horizontal dimensions are constrained by miniature component size requirements.
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 solution enhances welding efficiency and strength by allowing centralized wire management, improving the alignment and contact area of welding wires, preventing wire scattering and ensuring parallel, upright wire arrangement, thus addressing the challenges of miniaturized electronic component welding.
Implementation Method 1
S2. Electroplating, electroplate a metal layer with electroplating process onto the inner walls of the holes in each of the welding plates, such metal layer is a conductive layer for conducting the conductors on both sides of the welding plates
Implementation Method 2
S4. Cutting, cut each of the welding plates off the patch with a laser cutting machine
Data Source
AI summary
The present invention discloses an integrated miniature welding plate structure and manufacturing process therefor, which consists of pads with welded dots, welding wires and a welding plate; the manufacturing process of the welding plate consists of following steps: S1. Punching holes, take a SMT patch fixed with several welding plates, punch holes in the welding plates in accordance with the requirements; S2 Electroplating, electroplate a metal layer with electroplating process onto the inner walls of the holes in each of the welding plates; S3. Gluing, pour the insulation colloid into the holes in each of the welding plates, then electroplate a metal layer onto both ends of the colloid; S4. Cutting, cut each of the welding plates off the patch. The beneficial effects are: the welding wires are welded with the welding plates, then the welding plates are connected with the welded dots of the to-be-welded parts, the adopted welding method of the welding plates can improve the overall welding efficiency, ensure the welding strength of the welded dots and improve the welding quality; the structure design of the base plate and vertical plate is adopted for the welding plates, the welding wires are welded onto the vertical plates in a centralized manner, so the status that the welding wires not being parallel and upright can be obviously improved.