Laser Edge Welding of Flat Metal Interfaces Without Heavy Rollers
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Solution Overview
Problem
Existing methods for laser welding metal objects require large footprints and heavy rollers, limiting their integration in production environments and resulting in inefficient bonding processes.
Innovation Solution
A method involving laser welding of metal objects with parallel, contacting surfaces, where a laser beam is focused on the peripheral edge of the interface and moved along the interface, allowing the molten metals to form a strong bond without the need for extensive compression equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heavy rollers are used for compression of the plates, then a strong bond is achieved, but the device complexity and footprint increase
Solution Approach 1:
The patent replaces the mechanical roller compression system with a laser-based welding process. Instead of using heavy rollers to compress and bond the metal plates, a laser beam is used to melt and fuse the materials at the interface, eliminating the need for complex mechanical compression equipment while achieving strong bonds between dissimilar metals
Solution Approach 2:
The patent changes the bonding mechanism from mechanical compression to thermal processing. By controlling laser parameters (power, focal point position, scanning speed) and processing atmosphere, the method achieves strong bonds without requiring the mechanical pressure and complex equipment of roller systems
2Strength
If a laser beam is focused onto the peripheral edge and moved along the interface, then a strong bond over large area is achieved, but the processing time increases
Solution Approach 1:
The laser is positioned and focused at the peripheral edge of the interface before actual welding begins. This preliminary positioning ensures optimal energy distribution from the start, allowing the welding process to proceed efficiently along the interface without requiring repositioning or adjustment during operation
Solution Approach 2:
The laser beam is scanned or moved continuously along the interface in a controlled periodic manner, maintaining consistent heating and melting conditions throughout the welding process, which optimizes both bond strength and processing efficiency
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 achieves a strong, non-brittle bond over a large area between dissimilar metals like aluminum and copper, reducing the footprint and enabling easier integration into production environments.
Implementation Method 1
irradiating a laser beam with a focal point onto the peripheral edge in the direction of the interface
Implementation Method 2
melting both metals on either side of the interface while forming a strong bond
Data Source
Figure 1~3
AI summary
The invention relates to a method of joining a first and a second object, each object having a substantially flat surface. The method comprises the steps of: - Placing the objects with their surfaces in a contacting relationship along an interface, with their surfaces substantially parallel, the interface having a peripheral edge, - irradiating a laser beam with a focal point onto the peripheral edge in the direction of the interface while the plates are in a contacting relationship, and - moving the focal point of the laser beam along the interface in a direction transversely to the edge, to a position at a distance from the edge.