Curved Inner-Face Waveguide for Uniform Plastic Welding Energy
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Solution Overview
Problem
Existing waveguides for plastic welding, particularly in laser transmission welding, suffer from high energy losses and non-uniform energy distribution, which affect the quality and efficiency of the welding process.
Innovation Solution
The introduction of a negative waveguide with a continuously curved, concave-shaped inner face, optionally part of a spiral or ellipse, reduces beam interaction and enhances energy distribution by adapting to the welding seam contour, allowing for more efficient energy transfer and improved power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional waveguides with straight or simple curved inner faces are used, then the device structure is simple, but energy losses are high and power density distribution is non-uniform
Solution Approach 1:
The waveguide employs a continuously curved concave inner face (circular arc, parabola, or ellipse) instead of straight or simple curved surfaces. This curvature design optimizes laser beam reflection paths, reduces beam interaction losses, and achieves homogeneous power density distribution at the welding zone, directly resolving the energy loss problem while maintaining manufacturability through standard curved surface fabrication methods.
2Manufacturing precision
If conventional waveguides are used, then the manufacturing process is simple, but power density distribution at the welding seam is non-uniform
Solution Approach 1:
The inner face is designed with continuous curvature (circular arc, parabola, or ellipse) to achieve homogeneous power density distribution. These geometric forms can be manufactured using standard precision machining or molding techniques, balancing manufacturing feasibility with the requirement for uniform energy distribution at the welding seam.
Solution Approach 2:
The patent specifies optimal parameter ranges for the curved inner face geometry, including curvature radius (0.1-10mm), waveguide length (1-50mm), and thickness (0.5-5mm). By optimizing these parameters, the design achieves homogeneous power density distribution while keeping manufacturing complexity within acceptable limits.
3Manufacturing precision
If the waveguide inner face has a continuously curved concave shape, then homogeneous power density distribution is achieved, but the manufacturing complexity increases
Solution Approach 1:
The patent selects specific continuous curvature forms (circular arc, parabola, ellipse) that are mathematically simple and geometrically well-defined. These forms achieve homogeneous power density distribution while being manufacturable using conventional precision machining or injection molding techniques, avoiding the need for complex freeform surfaces.
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 design minimizes energy losses and ensures a homogeneous power density distribution, enabling stronger welds with reduced process times and increased tolerance for component misalignment.
Implementation Method 1
a first and a second inner face which are arranged between the entry end and the exit end, which are arranged opposite to each other and by means of which laser light can be reflected
Implementation Method 2
Positive waveguides consists of a solid state which guides laser light in the interior following the law of total internal reflection
Data Source
AI summary
A waveguide for plastic welding has an entry end, an exit end as well as a first and a second inner face arranged between the entry end and the exit end, which are arranged opposite to each other and by means of which laser light can be reflected. A first distance between the entry end and the exit end defines a length of the waveguide and a second distance between the first and the second inner face defines a thickness of the waveguide. The exit end may be arranged opposite to the entry end and a central plane of the waveguide may extend centrally from the entry end to the exit end. The first inner face comprises a continuously curved, concave shape so that a third distance between the first inner face and the central plane varies continuously from the entry end in the direction of the exit end.