Foil Laser Welding on Aluminum Fixtures Without Fixture Damage
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Solution Overview
Problem
Existing welding technologies are limited in their ability to weld foils together effectively, particularly with aluminum fixtures, and struggle with complex geometries and energy density issues, leading to potential damage and inefficiencies.
Innovation Solution
The use of an aluminum fixture with ridges and vacuum perforations, combined with blue or green laser wavelengths, to compress and weld foils together without welding the fixture, allowing for versatile welding paths and heat extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If green laser welding is used to weld foils, then welding capability is achieved, but energy density is insufficient to weld through to the supporting fixture
Solution Approach 1:
The patent changes the laser wavelength parameter from green to blue, which has higher energy density and better absorption characteristics for aluminum foils. This parameter change enables sufficient weld penetration through the foils to the supporting fixture while maintaining process reliability
2Strength
If aluminum is used in welding fixture structures with mechanical clamping, then fixture strength is achieved, but the fixture cannot serve as a direct-contact backing support
Solution Approach 1:
The aluminum fixture structure is designed to serve multiple functions: it provides mechanical support through its strength, enables direct-contact backing support for laser welding, and acts as a heat sink. The fixture transitions from a passive mechanical clamping device to an active participant in the welding process that enables higher energy density welding
3Reliability
If higher energy density is used to weld through foils, then weld penetration is improved, but the supporting fixture may be damaged
Solution Approach 1:
The aluminum fixture acts as an intermediary between the laser energy and the supporting structure. It absorbs and dissipates the high energy density laser beam, converting it to heat that is conducted away through the fixture's thermal mass and heat sink design, thereby protecting the supporting structure from direct laser damage while enabling sufficient weld penetration
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
Enables consistent welding of complex foil shapes with high throughput and reduced risk of fixture damage, achieving faster processing times and higher acceptance rates compared to current methods.
Implementation Method 1
activating a laser along the first weld location thereby welding the first and second foils together
Implementation Method 2
the lower section draws heat from the weld locations via the ridges
Implementation Method 3
inducing a vacuum between the first and second foils thereby compressing the first and second foils together over a first ridge
Data Source
AI summary
Systems and methods for welding first and second foils together. A method includes a step of positioning the first and second foils on a lower section of an aluminum fixture. The method further includes a step of compressing the first and second foils together over a first ridge of the lower section via an upper section of the aluminum fixture thereby defining a first weld location coinciding with the first ridge. The method further includes a step of activating a blue or green laser along the first weld location thereby welding the first and second foils together such that the aluminum fixture remains unwelded. Another method includes compressing first and second foils together over an aluminum fixture via a vacuum.