Folded Joint Geometry for Gap-Stable Laser Welding
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Solution Overview
Problem
Existing laser welding techniques face limitations in reducing welding failures such as cracks and blowholes due to gaps between workpieces, and the use of jigs restrict the area that can be irradiated, leading to incomplete welding.
Innovation Solution
A method involving the formation of a joint part with folded parts in plate-like portions, where the joint part is irradiated with a beam to inhibit gaps and improve seal performance and joint strength, allowing for effective laser welding without the need for a jig.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a jig is used to hold workpieces in contact with minimal gap, then welding failures are reduced, but the area that can be irradiated with beam is limited
Solution Approach 1:
The patent extracts the workpiece from the jig by forming a joint part with folded bases that self-align and maintain minimal gap without requiring external holding fixtures. This allows the beam to irradiate areas that would otherwise be blocked by the jig structure.
Solution Approach 2:
Instead of using a jig to hold workpieces from the outside, the patent inverts the approach by forming the alignment function into the joint part itself through folded bases that create self-aligning structures, eliminating the need for external jigs.
2Strength
If workpieces are held with minimal gap to reduce welding failures, then weld strength is improved, but the complexity of the manufacturing process increases due to jig requirements
Solution Approach 1:
The joint part with folded bases provides self-aligning and self-holding functionality, eliminating the need for external jigs and complex positioning fixtures. The structure itself ensures minimal gap and proper alignment during welding.
Solution Approach 2:
The patent merges the alignment, positioning, and gap control functions into the joint part structure itself through the folded bases, rather than requiring separate jig components. This integration simplifies the overall manufacturing system.
3Manufacturing precision
If the joint part is formed with folded bases facing each other, then gap inhibition is achieved, but the shape complexity of the joint part increases
Solution Approach 1:
The folded bases create curved or bent geometries that allow the joint part to accommodate dimensional variations and maintain minimal gap between workpieces. The curved shapes provide tolerance compensation while ensuring precise gap control.
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 method reduces welding failures by ensuring complete fusion of the joint parts, enhances seal performance, and prevents burn-through, while allowing for the formation of a flow path to inhibit fluid leakage.
Implementation Method 1
irradiating the joint part with a beam, thereby to perform laser welding
Data Source
AI summary
A method for manufacturing a joined body including two plate-like portions, the method including forming a joint part that comprises at least a portion of each of the two plate-like portions and joins the two plate-like portions; and irradiating the joint part with a beam, thereby to perform laser welding. The joint part includes at least one folded part, the at least one folded part is a bent part that is bent so as to be folded back in one of the two plate-like portions. First and second bases are formed at both ends of the bent part to face each other such that at least a portion of the other of the two plate-like portions is arranged between the first and second bases, the other of the two plate-like portions including no bent part.