Vehicle Lamp Cover Laser Welding Refraction Control
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Solution Overview
Problem
In seamless type vehicle lamps, the curved outer peripheral portion of the cover causes laser light refraction during laser welding, leading to uneven intensity and potential incomplete welding or resin decomposition, complicating the joining of the cover to the lamp housing.
Innovation Solution
The vehicle lamp design features a curved surface positioned on the outer peripheral side of the intersection point of a virtual line parallel to the welding leg's protruding direction, with an annular laser light incident surface, a parallel welding target surface, and a pressing direction perpendicular to the welding target surface, ensuring consistent laser light transmission and efficient force application during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the outer peripheral portion of the cover is formed as a curved surface to secure safety, then safety is improved, but laser light refraction occurs during welding causing uneven intensity and potential incomplete welding or resin decomposition
Solution Approach 1:
The cover is divided into two distinct surface regions: a curved surface portion for safety and a flat laser light incident surface portion for welding. This segmentation allows each portion to fulfill its specific function without interfering with the other, resolving the contradiction between safety and welding quality.
Solution Approach 2:
Different surface qualities are applied to different regions of the cover: the outer peripheral portion has a curved surface for safety, while the laser light incident surface is flat to ensure proper laser transmission. This local differentiation allows both safety and welding quality to be optimized in their respective regions.
2Ease of manufacture
If the curved surface is positioned to allow laser light incidence, then welding can proceed, but refraction causes biased intensity distribution on the welding surface
Solution Approach 1:
The cover surface is segmented into a curved portion and a flat laser incident surface portion. The flat surface is specifically positioned to receive laser light, ensuring uniform intensity distribution during welding, while the curved portion maintains safety without interfering with the welding process.
Solution Approach 2:
The flat laser light incident surface acts as an intermediary between the curved safety surface and the welding target. It receives laser light uniformly and transmits it to the welding surface without refraction, ensuring welding uniformity while allowing the curved surface to maintain safety.
3Adaptability or versatility
If the welding leg protrudes in various directions to match vehicle lamp design, then design flexibility is improved, but refraction occurs when laser light is incident at different angles
Solution Approach 1:
The cover is designed with different surface qualities in different regions: the outer peripheral curved surface provides safety, while the flat laser incident surface provides consistent laser transmission regardless of welding leg protrusion direction. This allows design flexibility to be maintained while ensuring manufacturing precision.
Solution Approach 2:
The solution addresses the directional variation of welding legs by introducing a new dimensional aspect - a flat surface oriented perpendicular to the laser light direction. This dimensional change ensures that laser light transmission consistency is maintained regardless of the welding leg's protrusion direction.
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 configuration ensures that the entire laser light reaches the welding surface without significant refraction, securing a strong and uniform joint between the cover and the lamp housing, even with variations in processing accuracy or laser light positioning.
Implementation Method 1
The welding leg is welded to the lamp housing by, for example, laser welding
Implementation Method 2
the emitted light is transmitted to the design surface of the cover of the one vehicle lamp and irradiated outward
Implementation Method 3
refraction occurs when the laser light is incident onto the design surface, and the intensity of the laser light irradiated on the welding surface is biased
Data Source
AI summary
A vehicle lamp includes a lamp housing having an inner space and a welding surface, and a cover disposed adjacent to another vehicle lamp, and configured to cover the inner space and join to the lamp housing by laser welding. The cover includes a design surface in which an outer surface of an outer peripheral portion is formed as a curved surface and a welding leg that protrudes from a portion near the outer peripheral portion in the design surface. An annular portion on an inner peripheral side of the curved surface on an outer surface of the design surface is formed as a laser light incident surface. The curved surface is positioned on an outer peripheral side from an intersection point of a virtual line and the outer surface of the design.