Laser-Cut Welding Tabs for Clean Processed Part Separation
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Solution Overview
Problem
Laser cutting methods face challenges in preventing the processed part from being caught in pin supports or falling due to the narrow cut slit created by fiber lasers, and existing solutions like micro joints require additional steps for removal of adhesive or melted residue.
Innovation Solution
A laser cutting method that forms a welding protruding-tab along the outline of the processed part, which is then bent and welded to the peripheral surface, allowing for reliable retention and easy separation without leaving traces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fiber laser is used for cutting, then cutting precision is improved, but the cut slit becomes narrow causing the processed part to be caught in pin supports or workpiece
Solution Approach 1:
The patent applies segmentation by dividing the retention mechanism into discrete welding protruding tabs positioned at specific locations around the processed part. These tabs are formed at segmented intervals along the cut outline, allowing the part to be retained without requiring a continuous narrow slit that would cause catching issues.
Solution Approach 2:
The welding protruding tabs serve as intermediary elements between the processed part and the workpiece. Instead of direct contact through a narrow slit that causes catching, the tabs act as mediators that provide retention through controlled welding points, eliminating the catching problem while maintaining precision.
2Reliability
If micro joint is used to connect processed part to workpiece, then processed part retention is improved, but additional removal steps are required
Solution Approach 1:
The patent changes the parameter of connection strength by using welding protruding tabs with controlled welding depth and area. The welding parameters (energy input, duration, position) are optimized to provide sufficient retention force during processing while allowing clean separation afterward, eliminating the need for additional removal steps required by micro joints.
Solution Approach 2:
The solution creates a composite structure where the processed part, welding protruding tabs, and workpiece form an integrated assembly during processing. The welding tabs act as a composite connection element that provides both retention and easy separation properties, combining the benefits of strong connection and easy removal in a single structure.
3Reliability
If adhesive or melted residue is used to prevent separation, then processed part retention is improved, but cleanup steps are required
Solution Approach 1:
The patent extracts the harmful elements (adhesives and melted residue) from the retention mechanism. Instead of using substances that require cleanup, the solution employs clean welding protruding tabs that provide retention through mechanical and metallurgical bonding without leaving residual materials that would complicate the process or require additional removal steps.
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 effectively retains the processed part for a long period with minimal residual impact, allowing for stable separation and improved control over retention forces compared to traditional micro joints.
Implementation Method 1
laser-cutting a processed part from a plate-shaped workpiece
Implementation Method 2
further melting an edge of a cut slit that is cut, by laser
Implementation Method 3
welding a free end of the welding protruding-tab to the peripheral surface of the processed part
Implementation Method 4
forming an outline slit by performing laser-cutting along the outline of the processed part and welding a free end of the welding protruding-tab
Data Source
AI summary
In a laser cutting method, a cut slit of a welding protruding-tab configured to be bent by laser cutting along an outline of a processed part and press a peripheral surface of the processed part is laser-cut in advance in a periphery of the processed part that is cut from a workpiece, and an outline slit is formed by performing laser cutting along the outline of the processed part and a free end of the welding protruding-tab is welded to the peripheral surface of the processed part. According to the above described laser cutting method, it is possible to retain the processed part reliably and stably for a long period, and it is possible to easily separate the processed part from the workpiece with almost no trace left on the processed part.