Laser Diode Array Heating for Thermoplastic Reinforcement
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Solution Overview
Problem
Existing methods for producing reinforcement structures on molded bodies, such as pressure vessels, face challenges in achieving stable connections between thermoplastic materials and substrates, particularly under high pressure conditions, due to uneven temperature distribution and mechanical stress during the bonding process.
Innovation Solution
A device utilizing a laser diode array with an uneven intensity distribution to heat the thermoplastic strip, ensuring uniform temperature across its thickness, combined with a pressing mechanism and a traversing device, allows for a stable and efficient application of the reinforcement structure, reducing mechanical and thermal stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If uniform laser radiation is applied to heat the thermoplastic strip, then the heating process is simple, but uneven temperature distribution occurs across the strip thickness leading to poor adhesion
Solution Approach 1:
The patent applies local quality by creating an uneven laser radiation intensity distribution specifically tailored to the heating requirements of the strip. The laser is designed to emit higher intensity radiation at the edges and lower intensity at the center of the strip width, matching the heat dissipation pattern where edges cool faster. This localized variation in radiation quality achieves uniform temperature distribution without requiring complex mechanical heating systems.
2Strength
If thicker strips are used to improve reinforcement, then structural strength increases, but heating time and production time increase
Solution Approach 1:
The patent changes the laser radiation parameter (intensity distribution) to optimize heating efficiency. By adjusting the spatial distribution of laser intensity rather than increasing total energy input or heating time, the system can effectively heat thicker strips without proportionally increasing production time. The uneven intensity profile ensures that all regions of the strip reach optimal bonding temperature simultaneously, maintaining productivity while enabling use of thicker reinforcement materials.
3Reliability
If high pressure is applied to ensure bonding, then adhesion improves, but mechanical stress and deformation increase
Solution Approach 1:
The patent replaces the mechanical heating system (heating elements in contact with the strip) with an optical system (laser radiation). This substitution eliminates the need for complex mechanical pressure and contact systems, reducing mechanical stress on the reinforcement structure. The laser provides non-contact heating that achieves uniform temperature distribution through controlled radiation intensity, thereby improving adhesion without introducing significant mechanical stress or deformation.
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 approach results in a more stable reinforcement structure with improved adhesion and reduced thermal stresses, enabling the use of thicker strips and faster production times, enhancing the structural integrity of pressure vessels under high pressure conditions.
Implementation Method 1
at least one laser diode array with a large number of laser diodes for irradiating a heating surface of the strip upstream of the pressing region of the strip in the pulling direction and/or a heating surface of the shaped body downstream of the pressing region
Implementation Method 2
the strip is locally melted in the area of its heating surface and/or the surface of the shaped body in the region of its heating surface, so that the strip is connected to the shaped body
Implementation Method 3
a pressing device for pressing the band onto the surface of the shaped body... the band is subjected to a force in the direction of the surface of the mold by means of the pressing device
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
The present invention discloses a device for producing a reinforcing structure (20), which comprises a strip (30) that is fibre-reinforced and comprises thermoplastic material, on the surface of a moulding (11). The device is characterized in that a laser diode array (110, 120) is adapted for irradiating a radiation zone so as to bring about such an uneven intensity distribution on a heating-up area (32) of a strip (30) from which the reinforcing structure (20) is formed that the radiation intensity on the heating-up area (32) of the strip (30) decreases at least in certain portions in a drawing direction R2.