Resilient Connection Lug for Gap-Free Laser Welding Contact
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Solution Overview
Problem
In compact electronic circuits, achieving a gap-free mechanical and electrical connection between welding partners is challenging due to space constraints and misalignment issues, leading to potential metal ejections and poorly welded contacts during laser welding.
Innovation Solution
A connecting lug with a bending leg and a compensation angle is designed to allow for positional correction, enabling a gap-free welding contact by bending and aligning with a contacting partner, eliminating the need for a counter bearing and allowing one-sided force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a tong-like device is used to compress welding partners to achieve zero gap, then gap-free contact is achieved, but device complexity and space requirements increase
Solution Approach 1:
The connection lug serves itself by using its own elastic deformation capability to achieve gap-free contact. The flexible bending leg automatically adjusts its position when force is applied, eliminating the need for external tong-like compression devices and their associated counter bearings.
Solution Approach 2:
The connection lug's mechanical properties are changed by introducing elasticity through the flexible bending leg. This allows the rigid connection Lug to become adaptively flexible during the welding process, enabling gap-free contact without complex external devices.
2Manufacturing precision
If a tong-like device is used for compression welding, then gap-free contact is achieved, but ease of operation deteriorates due to difficult handling and access requirements
Solution Approach 1:
The connection Lug automatically achieves the correct position through its own elastic deformation when force is applied from one side. This eliminates the need for operators to manually position and coordinate both sides of the welding partners, significantly improving ease of operation.
3Speed
If laser welding is performed with a gap between welding partners, then welding speed is maintained, but reliability deteriorates due to metal ejections and unwelded contacts
Solution Approach 1:
The connection Lug is pre-formed with a flexible bending leg that is prepared in advance to enable elastic deformation. This preliminary preparation allows the connection surface to be automatically positioned flush with the contacting partner just before welding, ensuring reliable gap-free contact without sacrificing welding speed.
4Strength
If the connection Lug is made rigid to maintain structural integrity, then strength is improved, but adaptability deteriorates due to inability to compensate for misalignments
Solution Approach 1:
The connection Lug is segmented into a rigid connection body and a flexible bending leg. The rigid body maintains structural integrity and strength, while the flexible bending leg provides adaptability for misalignment compensation. This segmentation allows both requirements to be satisfied simultaneously.
Solution Approach 2:
Different parts of the connection Lug have different mechanical properties. The connection body remains rigid for strength, while the bending leg is made flexible locally to provide adaptability. This local quality differentiation resolves the contradiction between strength and adaptability.
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 design ensures a reliable, gap-free welding contact is formed efficiently, compensating for misalignments and reducing the risk of metal ejections, while maintaining the structural integrity of the electronic component.
Implementation Method 1
the terminal lug is designed to be flexible such that, when a force is applied from the connection side to a contact partner that is flat at least in this area on the free end of the bending leg, the positional orientation of the connection surface can be adjusted at least counter to the compensation angle until the connection surface rests on the flat contact partner without a gap
Implementation Method 2
This is used, for example, for welding power contacts of power modules within electronic power circuits. The two welding partners - for example the power contact and a connection point of the electronic circuit - must be brought very close together, usually with a gap width of less than 100μm.
Data Source
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Figure 3~4
AI summary
The invention proceeds from an electrical and/or electronic component having at least one external electrical connection contact. Said external electrical connection contact is designed as a connection lug which is attached on one side and has the purpose of making electrical contact with a contact-making partner. In this case, in order to make electrical contact the connection lug has a connecting side with a planar connecting area. The exposed end of the connection lug has a bending limb which is bent out of the plane towards the connecting side through a compensation angle. In this case, the bending limb has the connecting area. Furthermore, the connection lug is designed in a resilient manner in such a way that when a contact-making partner, which is planar at least in this region, makes contact with the free end of the bending limb with force applied from the connecting side, positional orientation of the connecting area can be adjusted at least counter to the compensation angle until gap-free contact is achieved between the connecting area and the planar contact-making partner.