3D Laser Joining Mask Layout for Free-Form Workpiece Bonding
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Solution Overview
Problem
Conventional mask welding processes struggle with bonding 3D workpieces having distinct free-form surfaces due to divergence of the laser beam and refraction issues, leading to reduced projection accuracy and limited applicability.
Innovation Solution
The method involves creating mask structures on the bearing side of the clamping element or the second contour side of the first workpiece, using a clamping element that is a negative mold of the first workpiece, with reflective materials to direct laser light only to the bonding contact faces, reducing divergence and refraction effects, and allowing for even clamping pressure across non-planar surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a mask is disposed at a vertical distance above the free-form surface of a 3D workpiece, then the workpiece can be clamped and processed, but the projection accuracy of the mask structures deteriorates due to laser beam divergence and refraction
Solution Approach 1:
The clamping element serves as an intermediary carrier that integrates both clamping function and mask structure projection. By forming mask structures directly on the clamping element's bearing side, the system eliminates the need for a separate mask disposed at a distance, thereby maintaining projection accuracy while preserving clamping capability for 3D workpieces
Solution Approach 2:
The invention merges the clamping element and mask into a single integrated component. The mask structures are created directly on the bearing side of the clamping element, combining the functions of clamping and pattern projection into one element, which resolves the contradiction between maintaining operational ease and ensuring manufacturing precision
2Adaptability or versatility
If the mask is located far from the welding plane to accommodate 3D workpiece height, then the workpiece can be processed, but the projection accuracy grows worse due to increased distance and beam divergence
Solution Approach 1:
The clamping element acts as an intermediary that bridges the gap between the laser source and the welding plane. By positioning the mask structures on the clamping element rather than above the workpiece, the system maintains a consistent, minimal distance between the mask and welding plane, ensuring high projection accuracy while accommodating various 3D workpiece geometries
Solution Approach 2:
The mask structures on the clamping element create a direct optical copy of the bonding pattern at the welding plane. This copying mechanism occurs at minimal distance, eliminating the projection errors that would occur with distant mask placement, while the clamping element's adaptability allows processing of diverse 3D workpiece shapes
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 enhances the accuracy and efficiency of laser joining for 3D workpieces with free-form surfaces by maintaining consistent contact pressure and reducing refraction errors, enabling reliable bonding of complex shapes.
Implementation Method 1
the first workpiece facing the laser source is made of a material transparent to the laser beam and the other second workpiece is made of a material absorbent to the laser beam, so that the bonding contact faces of the two workpieces abutting one another melt under the action of laser light
Implementation Method 2
a mask having mask structures is used, which allows laser light to pass only in the region of the bonding contact faces so as to plasticize only the bonding contact faces on the second workpiece
Data Source
AI summary
A laser joining method and device includes a pressure-applying clamping device, which presses a first and a second workpiece against one another at least after the workpieces have been locally plasticized, and a mask having mask structures, which allow laser light to pass only in the region of the bonding contact faces, wherein at least the workpiece facing the laser source is formed by a three-dimensional molded part, which is not planar at least on the first contour side facing the clamping element and/or on the second contour side facing the second workpiece, and wherein the clamping element, with the bearing side thereof for the first workpiece, is adapted to the first contour side of the first workpiece. The mask structures are created on the bearing side of the clamping element facing the first workpiece or on the second contour side of the first workpiece facing the second workpiece.