Drawer Side Wall Laser Welding Using Embossing for Energy Absorption
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Solution Overview
Problem
Existing methods for producing side walls for drawers using metallic support and hollow profiles connected by laser welding face challenges such as difficult access for lasers due to narrow profiles, leading to inefficient energy use, reflection issues, and potential weakening of the welds.
Innovation Solution
Incorporating embossings on the support and hollow profiles to enhance energy absorption of laser light, allowing for deeper and more efficient laser welding connections while reducing reflection and improving the structural integrity of the side wall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the support profile is made narrow to increase storage space and aesthetics, then the storage capacity and appearance are improved, but the laser access becomes difficult and welding quality deteriorates
Solution Approach 1:
The embossing is created on the support profile before the laser welding process. This preliminary structural modification prepares the surface to enhance laser energy absorption and facilitate proper laser access, thereby resolving the contradiction between narrow profile design and welding quality.
Solution Approach 2:
The embossing creates localized structural features at specific positions on the support profile where laser welding will occur. This local modification changes the surface properties and geometry only in the welding region, allowing the rest of the profile to remain narrow while ensuring high-quality welding at the connection points.
2Ease of operation
If the laser is positioned at a distance to access deep welding positions, then the accessibility is improved, but the laser energy efficiency deteriorates due to reflection and energy loss
Solution Approach 1:
The embossing creates curved or angled surface features that redirect laser light at favorable angles. This curvature allows the laser to access deep welding positions while maintaining efficient energy coupling, reducing reflection losses and improving energy utilization.
Solution Approach 2:
The embossing modifies the surface geometry parameters (angle, depth, shape) to optimize laser energy absorption. By changing the surface parameters through embossing, the system achieves both good laser accessibility and high energy efficiency simultaneously.
3Strength
If high laser power is used to overcome reflection and achieve proper welding, then the welding penetration is improved, but the energy consumption and heat damage increase
Solution Approach 1:
The embossing converts the harmful reflection effect into a beneficial one by strategically directing reflected laser light back onto the welding zone or onto adjacent areas that also require heating. This transforms energy that would be lost into useful heating, improving penetration while reducing overall energy consumption.
Solution Approach 2:
The embossing changes the optical parameters of the surface (reflectivity, absorption, emission) through its geometric structure. This allows the system to achieve deep penetration with lower laser power by optimizing the energy coupling efficiency at the material surface.
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 use of embossings reduces the required laser power, improves the quality and strength of the laser welded connections, and allows for the creation of narrower, more aesthetically pleasing drawer side walls with increased storage capacity.
Implementation Method 1
at least one embossing for increasing an energy absorption of laser light from at least one laser for forming the at least one laser welded connection
Implementation Method 2
the at least one embossing is melted at least in some regions during welding
Implementation Method 3
the at least one embossing is melted at least in some regions during welding
Implementation Method 4
the at least one support profile and the at least one hollow profile are welded to one another by at least one laser welded connection
Data Source
AI summary
A method is provided for producing a side wall for a drawer, the drawer including a support profile consisting at least partially of a metallic material and a hollow profile consisting at least partially of a metallic material. The method includes welding the support profile and the hollow profile to one another by a laser welded connection. The support profile and/or the hollow profile are provided with an embossing prior to welding to increase an energy absorption of laser light of the laser to form the laser welded connection in a region and/or around the region of the laser welded connection, and the embossing is at least partially melted during the welding.