Terminal Fixing Structure Using Penetrating Hole and Laser Brazing
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Solution Overview
Problem
Existing techniques for fixing terminals to conductive patterns using laser beams are limited by the time required for solder wetting phenomena, which hinders further reduction in laser irradiation time per terminal.
Innovation Solution
A method and structure involving the formation of a penetrating hole in the terminal, which is gradually widened and filled with brazing filler metal using a laser beam, allowing for terminal fixation without relying on wetting phenomena, thereby reducing laser irradiation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wetting phenomena are used to fix the terminal to the conductive pattern, then the terminal can be securely fixed, but the laser beam irradiation time per terminal increases to several hundred msec
Solution Approach 1:
A penetrating hole is formed in advance in the terminal before the laser bonding process. This preliminary structural preparation allows the brazing filler metal to be efficiently guided and contained during the bonding process, eliminating the need for prolonged wetting phenomena and reducing the laser irradiation time while maintaining secure fixation.
Solution Approach 2:
A brazing filler metal is introduced as an intermediary material between the terminal and the conductive pattern. The filler metal fills the pre-formed penetrating hole and facilitates bonding, replacing the reliance on wetting phenomena and enabling faster laser irradiation times of 100 µsec or less while ensuring reliable fixation.
2Productivity
If the laser beam irradiation time is reduced to improve productivity, then productivity increases, but the terminal may not be properly fixed when relying on wetting phenomena
Solution Approach 1:
The penetrating hole is formed in advance in the terminal, creating a structural feature that guides and contains the brazing filler metal. This preliminary preparation ensures that even with reduced laser irradiation time of 100 µsec or less, the filler metal is properly positioned and bonded, maintaining fixation reliability while improving productivity.
Solution Approach 2:
The bonding mechanism is changed from relying on wetting phenomena to using a brazing filler metal that fills a pre-formed penetrating hole. This parameter change in the bonding approach allows for significantly reduced laser irradiation time while maintaining or improving fixation reliability, thereby enhancing productivity.
3Loss of time
If a penetrating hole is formed in the terminal and filled with brazing filler metal, then the laser beam irradiation time is reduced to 100 µsec or less, but the structure becomes more complex
Solution Approach 1:
The terminal structure is segmented by forming a penetrating hole through it, dividing the terminal into upper and lower portions. This segmentation creates a pathway for the brazing filler metal and enables the rapid bonding process, reducing laser irradiation time to 100 µsec or less. The added structural element is offset by the significant time savings in the bonding process.
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 enables faster fixation of terminals by eliminating the need for wetting, allowing for quicker and more efficient use of brazing filler metal, and provides visual confirmation of the fixation by the presence of the filler metal at the terminal's surface.
Implementation Method 1
forming a penetrating hole in the terminal by irradiating a laser beam onto the terminal
Implementation Method 2
the penetrating hole is filled with the brazing filler metal melted by the irradiation of the laser beam
Implementation Method 3
the penetrating hole is filled with the brazing filler metal melted by the irradiation of the laser beam
Implementation Method 4
the penetrating hole is filled with the brazing filler metal melted by the irradiation of the laser beam
Implementation Method 5
A penetrating hole is formed in the terminal, the penetrating hole being gradually widened in a direction apart from the substrate. The penetrating hole is filled with the brazing filler metal.
Data Source
AI summary
A fixing method for fixing a terminal to a conductive pattern with a brazing filler metal disposed therebetween includes: a first step of disposing the brazing filler metal on the conductive pattern; a second step of bringing the terminal into contact with the brazing filler metal; and a third step of forming a penetrating hole in the terminal by irradiating a laser beam onto the terminal. In the third step, the laser beam is irradiated onto the terminal in such a manner that the penetrating hole is filled with the brazing filler metal melted by the irradiation of the laser beam.