Resin Wall Inclined Surface Laser Soldering
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Solution Overview
Problem
Substrates with resin molding around lands are prone to damage during soldering processes, especially when using laser soldering, due to diffuse reflection causing melting of the resin wall, and when using a soldering iron, there's a risk of collision with the resin wall if not accurately aligned.
Innovation Solution
A substrate design featuring a resin wall with an inclined surface greater than 90° relative to the land, a highly reflective color with reflectance of not less than 60%, and a groove to house the wire tip, positioned off-center, which secures the wire's position and reduces diffuse reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a perpendicular resin wall is formed around the land, then the land is clearly defined and wire positioning is facilitated, but the resin wall is prone to damage from soldering iron contact and laser beam diffuse reflection
Solution Approach 1:
The resin wall is designed with an inclined surface instead of a perpendicular shape. The inclined surface is angled at 45 degrees or more (preferably 60 to 80 degrees) relative to the land surface, creating an asymmetric geometry that deflects laser beams away from the resin wall while maintaining clear wire positioning guidance
Solution Approach 2:
The inclined resin wall surface converts the harmful diffuse reflection of laser beams into a beneficial deflection mechanism. By angling the surface, the reflection directs heat away from the resin wall, preventing melting while the surface still provides positioning guidance for the wire
2Extent of automation
If laser soldering is used to solder the wire tip to the land, then automated soldering is achieved, but diffuse reflection from the land or wire may melt the surrounding resin wall
Solution Approach 1:
The asymmetric inclined surface geometry (45 degrees or more) strategically deflects laser beams that undergo diffuse reflection, directing them away from the resin wall to prevent melting while enabling automated laser soldering processes
Solution Approach 2:
The solution addresses the two-dimensional problem of laser reflection by introducing a three-dimensional inclined surface element. The angled surface adds a spatial dimension to beam deflection, redirecting reflected laser energy in a different spatial direction that avoids the resin wall
3Loss of substance
If the land surface area is reduced to minimize material usage, then manufacturing cost is reduced, but the risk of resin wall damage increases due to更难 accurate soldering alignment
Solution Approach 1:
The inclined resin wall creates an asymmetric protective geometry that becomes increasingly effective as the land size decreases. The angled surface provides a larger safety margin for soldering alignment errors on smaller lands, allowing material reduction without proportionally increasing damage risk
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
Prevents damage to the resin wall during soldering by minimizing contact and reflection, ensuring reliable soldering without melting the resin and securing the wire's position for consistent soldering.
Implementation Method 1
diffuse reflection of the laser beam from the land 13 may irradiate the resin wall 12 surrounding the land 13, melting the resin wall 12
Implementation Method 2
the wall has a color with a reflectance of not less than 60%
Data Source
AI summary
The present invention provides a substrate provided with a land to which the tip of a magnetic wire is to be soldered and a resin wall formed around and higher than the land. The resin wall has an inclined surface inclined at an angle greater than 90° with respect to the land.