Connector Terminal Laser Welding with Dummy Lands for Odd Pin Layouts
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Solution Overview
Problem
The prism method of laser soldering used to fix connector terminals to a substrate results in defects such as burning when the pin arrangement is odd, as an extra laser beam irradiates a non-terminal area, causing damage to the substrate.
Innovation Solution
A terminal fixing method that includes constructing lands with both terminal installation lands and larger dummy lands, and irradiating laser beams to these lands to prevent substrate damage while improving productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the prism method is employed to simultaneously irradiate two laser beams toward two lands, then productivity is improved by fixing two connector terminals simultaneously, but when the pin arrangement is an odd number, one laser beam irradiates a portion where no connector terminal is present, causing the FPC to be burned and insulation appearance to become defective
Solution Approach 1:
The patent introduces a dummy land as an intermediary target for the excess laser beam. When an odd number of connector terminals are present, one laser beam is directed to the dummy land instead of irradiating the FPC directly. This mediator absorbs the laser energy that would otherwise cause burning, while the dummy land's larger area ensures the beam is properly absorbed without damaging the actual circuit board.
Solution Approach 2:
The patent converts the potentially harmful excess laser beam into a beneficial effect by directing it to the dummy land. The dummy land serves as a sacrificial target that absorbs the harmful radiation, transforming what would be a destructive force into a controlled energy dissipation mechanism that protects the actual circuit board from damage.
2Manufacturing precision
If two laser beams are applied to each of the plurality of lands and connector terminal when the number of lands is an odd number, then the last land and one connector terminal remain, but the other laser beam irradiates the FPC causing burning
Solution Approach 1:
The dummy land acts as an intermediary target that receives the excess laser beam when the number of lands is odd. This mediator structure ensures proper laser beam positioning and energy absorption without causing burning of the actual circuit board, maintaining manufacturing precision while preventing harmful effects.
Solution Approach 2:
The patent prepares the dummy land in advance as a designated target for excess laser beams. By pre-positioning this sacrificial target, the system is ready to handle odd-numbered pin arrangements without causing damage, allowing the laser beam positioning to be maintained precisely while preventing FPC burning.
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 substrate damage during laser welding by using dummy lands to absorb excess heat, ensuring even laser beam distribution and maintaining productivity.
Implementation Method 1
the solder is temporarily melted by the laser beam
Implementation Method 2
the solder is temporarily melted by the laser beam
Implementation Method 3
the solder is solidified to fix the connector terminals to the lands of the FPC
Implementation Method 4
the two laser beams emitted from one laser oscillator and divided into two by the prism
Data Source
AI summary
A terminal fixing method, for fixing one or more terminals to a plurality of lands provided on a substrate by laser welding, includes: constructing the plurality of lands by one or more terminal installation lands on which the terminals are installed and one or more dummy lands each larger than each of the terminal installation lands; irradiating each of divided laser beams emitted from a laser oscillator toward a corresponding land of two or more lands in the plurality of lands by the laser welding; and constructing the two or more lands by two or more terminal installation lands in the terminal installation lands, or one or more terminal installation lands in the terminal installation lands and the one or more dummy lands.