Dielectric-Coated Composite Welding for Reflective Metal Substrates
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Solution Overview
Problem
Laser welding of composite materials with high reflectivity surfaces faces inefficiencies due to energy distribution issues and complex alignment requirements, particularly when welding convex surfaces, leading to unstable welds and poor heat transfer.
Innovation Solution
A dielectric coating with a thickness of 140 nm to 210 nm is applied to the substrate, allowing the laser beam to be focused at an orientation angle of 2° to 50°, increasing energy absorption to at least 15%, thereby enhancing the welding process efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a dielectric coating is applied to increase energy absorption, then welding efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies a dielectric coating with specific thickness parameters (140 nm to 210 nm) on the aluminum substrate to optimize laser energy absorption. By controlling the coating thickness within this range, the structure achieves at least 15% energy absorption while maintaining a relatively simple manufacturing process through anodization or electrolytic brightening followed by anodic oxidation.
2Use of energy by moving object
If the laser beam is focused at an acute orientation angle, then energy absorption is improved, but alignment precision requirements increase
Solution Approach 1:
The patent specifies orienting the laser beam at an acute angle (2° to 50°) relative to the substrate surface normal to maximize energy absorption by the dielectric-coated aluminum. This angular parameter optimization enables efficient welding while the dielectric coating provides a consistent reference surface that helps maintain alignment precision.
3Productivity
If the dielectric coating thickness is increased to improve energy absorption, then welding efficiency improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent defines a specific thickness range (140 nm to 210 nm) for the dielectric coating to achieve optimal laser energy absorption. This range is sufficiently narrow to ensure consistent performance but wide enough to accommodate normal manufacturing variations through standard anodization and electrolytic brightening processes followed by anodic oxidation.
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
The method achieves increased energy absorption and improved weld stability by focusing the laser beam onto the composite material, resulting in efficient energy utilization and enhanced heat transfer during the welding process.
Implementation Method 1
a dielectric coating is situated at least on the first side... the radiated-in energy of the laser beam L is absorbed to the extent of at least 15 percent
Implementation Method 2
a laser beam L is projected at an acute orientation angle μ with respect to the surface of the substrate S... in order to produce a continuous weld seam or discrete weld spots
Implementation Method 3
a layer which is composed of anodically oxidized or electrolytically brightened and anodically oxided aluminum
Data Source
AI summary
The invention relates to a method for the laser welding of a composite material (V) to a component (11) in particular for the production of a solar collector element (E), wherein the composite material (V) comprises a strip-shaped substrate (1) composed of a metal having high reflectivity to laser radiation, said substrate having a first side (A) and a second side (B), wherein a dielectric coating (7) is situated at least on the first side (A), and wherein, in order to produce a weld seam, a laser beam (L) is projected at an acute orientation angle (μ) at least onto the first side (A) of the substrate (1) provided with the dielectric coating (7). In order to improve the energy efficiency of the laser radiation used, it is proposed that the dielectric coating (7) has a thickness (DB) in the range of 140 nm to 210 nm and the laser beam (L) is radiated in at an orientation angle (μ), in particular in focused fashion, in such a way that the radiated-in energy of the laser beam (L) is absorbed to the extent of at least 15 percent.