US4230930A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Laser welding method for electrical wire connection to a terminal pin of an exhaust gas sensor
Assignee: Ford Motor Co
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Filing: 1979-01-25
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Granted: 1980-10-28
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Expires: 1999-01-25
Abstract
Abstract A method for welding an electrical lead wire to a terminal pin with the use of a laser beam. The method is particularly designed for use in welding an electrical lead wire of an exhaust gas sensor to a terminal pin having an opening through which the electrical lead wire extends to the exterior of the pin. The lead wire may be made of nichrome material and the terminal pin from leaded steel. The laser beam is positioned vertically above the extended portion of the lead wire and its focal point is above the end of the lead wire. No separate filler metal is required since the lead wire material is itself available as a filler material.
Inventors
- 👤 Uck I. Chang
- 👤 Kenneth W. Casey
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 22:11
CPC Classifications
G; G01; G01N; G01N27/00; G01N27/26; G01N27/403; G01N27/406; G01N27/407; B; B23; B23K; B23K26/00; B23K26/20; B23K26/21; B23K26/22; G01N27/4062; H; H01; H01R; H01R43/00; H01R43/02; B23K2103/00; B23K2103/02; B23K2103/04
Claims Analysis
Total Claims: 12
Claim 1
Independent Claim
226 words
A method for welding an electrical lead wire to a terminal pin, the terminal pin having a head with an internal opening, the electrical lead wire being received within the opening and having a portion extending to the exterior of the terminal-pin head, the method comprising the steps of: (a) supporting the terminal pin with the head thereof being located such that the portion of the electrical lead wire extending therefrom is substantially vertical and the exterior portion of the lead wire has its end terminating a predetermined distance above the terminal-pin head; (b) positioning a laser beam source above the exterior portion of the lead wire; (c) causing the laser beam from the source to be propagated in a direction substantially coinciding with the force of gravity, the laser beam having a focal point located above the electrical lead wire end and the laser beam impinging on the end of the electrical lead wire and on the head of the terminal pin; and (d) applying the laser beam to the electrical lead wire and terminal-pin head, as specified in step (c) above, for a time period sufficient to enable the end of the electrical lead wire to liquify, to progressively move in the liquified state toward the terminal-pin head, and thereafter to coalesce with metal in the terminal-pin head concurrently liquified by the laser beam.
Claim 2
Independent Claim
226 words
A method for welding an electrical lead wire to a terminal pin, the terminal pin having a head with an internal opening, the electrical lead wire being received within the opening and having a portion extending to the exterior of the terminal-pin head, the method comprising the steps of: (a) supporting the terminal pin with the head thereof being located such that the portion of the electrical lead wire extending therefrom is substantially vertical and the exterior portion of the lead wire has its end terminating a predetermined distance above the terminal-pin head; (b) positioning a laser beam source above the exterior portion of the lead wire; (c) causing the laser beam from the source to be propagated in a direction substantially coinciding with the force of gravity, the laser beam having a focal point located above the electrical lead wire end and the laser beam impinging on the end of the electrical lead wire and on the head of the terminal pin; and (d) applying the laser beam to the electrical lead wire and terminal-pin head, as specified in step (c) above, for a time period sufficient to enable the end of the electrical lead wire to liquify, to progressively move in the liquified state toward the terminal-pin head, and thereafter to coalesce with metal in the terminal-pin head concurrently liquified by the laser beam.
Claim 3
Dependent Claim
19 words
A method for welding according to claim 1, wherein the coalescence is achieved in the absence of filler metal.
Claim 4
Dependent Claim
59 words
A welding method according to claim 1, wherein the coalescence of the electrical lead wire and the liquified terminal-pin head material forms an electrical connection between the terminal pin and the lead wire, seals the opening in the terminal pin from which the electrical lead wire extended, and forms a gas-tight seal at the end of the terminal-pin head.
Claim 5
Dependent Claim
22 words
A welding method according to claim 2, wherein the compositions of the terminal pin and the electrical lead wire are substantially different.
Claim 6
Dependent Claim
26 words
A welding method according to claim 4, wherein the terminal pin is formed from a steel composition and the electrical lead wire from a nickel-chrome composition.
Claim 7
Dependent Claim
32 words
A welding method according to claims 1 or 2, wherein the opening in the terminal-pin head has a cross-section substantially larger in area than the cross-sectional area of the electrical lead wire.
Claim 8
Dependent Claim
49 words
A welding method according to claims 1 or 2, which further includes the step of controlling the distance from the focal point of the laser beam to the end of the electrical lead wire prior to application of the laser beam to such end of the electrical lead wire.
Claim 9
Dependent Claim
34 words
A welding method according to claim 7, wherein the power density of the laser beam impinging on the end of the electrical lead wire is varied during the application of the laser beam thereto.
Claim 10
Dependent Claim
29 words
A welding method according to claim 7, wherein the terminal-pin material is made from a leaded steel composition and the electrical lead wire is made from a nickel-chrome composition.
Claim 11
Dependent Claim
20 words
A welding method according to claim 9, wherein the terminal pin material is leaded steel having a nickel plating thereon.
Claim 12
Dependent Claim
29 words
A welding method according to claim 10, wherein the nickel plating on the terminal pin is dull in appearance and has been applied over a flash plate of copper.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1983-10-28 | 1984-04-28 | 1984-10-28 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1987-10-28 | 1988-04-28 | 1988-10-28 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1991-10-28 | 1992-04-28 | 1992-10-28 | $7700.00 | Window Closed / Lapsed |